Hyster A419 Service Manual - PDF DOWNLOAD

AC MOTOR REPAIR P2.0 [A290]; W45ZHD [A419]

PART NO. 4035859

0620 SRM 1513

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR •

• • • • • • • • • • • • • •

The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the product. Updated technical service information may be available from your local authorized Hyster® dealer. Service Manuals provide general guidelines for maintenance and service and are intended for use by trained and experienced technicians. Failure to properly maintain equipment or to follow instructions contained in the Service Manual could result in damage to the products, personal injury, property damage or death.

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 when making 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.

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury and property damage.

On the lift truck, the WARNING symbol and word are on orange background. The CAUTION symbol and word are on yellow background.

Table of Contents

TABLE OF CONTENTS General .....................................................................................................................................................................1 Accessing the Drive Unit Compartment ............................................................................................................1 Accessing the Drive Unit Compartment ............................................................................................................2 Special Precautions ................................................................................................................................................. 3 Discharging the Capacitors ................................................................................................................................ 3 Description ...............................................................................................................................................................4 AC Motor Repair ......................................................................................................................................................4 Remove ................................................................................................................................................................ 4 Disassemble .........................................................................................................................................................4 Inspect ................................................................................................................................................................. 7 Assemble ..............................................................................................................................................................7 Install ...................................................................................................................................................................7 Troubleshooting .......................................................................................................................................................8 This section is for the following models: P2.0 [A290]; (W45ZHD) [A419]

©2015 HYSTER COMPANY

i

"THE QUALITY KEEPERS" HYSTER APPROVED PARTS

0620 SRM 1513

General

General This section contains repair and maintenance procedures for the AC traction motor. Additional information concerning the traction motor may be included in other sections when the information is more closely related to other systems. Sections that may contain related information include: •

Periodic Maintenance 8000SRM1510 for lift truck model A290

•

Periodic Maintenance 8000SRM1666 for lift truck model A419

•

Steering Mechanism 1600SRM1504

•

Electrical System 2200SRM1508

1. DRIVE UNIT COMPARTMENT COVER 2. NUTS

ACCESSING THE DRIVE UNIT COMPARTMENT The drive unit compartment is concealed behind a molded cover which fits securely around the drive unit and steer support to the frame.

To remove the drive unit cover, first remove the two nuts securing the cover to the frame. Starting at the top left edge of the cover and with both hands pull the cover away from the frame until the cover kicks out from the retaining clips. Repeat this for the right side of the cover. Work around the edge of the cover until free from the truck. See Figure 1.

3. RETAINING CLIPS 4. FRAME

Figure 1. Drive Unit Compartment Cover A290

1

General

0620 SRM 1513

To install the drive unit cover, place the bottom of the drive unit cover onto the frame and position the lower edges partially into the lower retaining clips.

Align the holes in the cover with the mounting studs attached to the frame. Push the top of the cover partially into the upper retaining clips. Do not push either edge of the cover in completely in before starting all edges into the proper place.

When the cover is aligned and started properly, press the cover completely into the retaining clips.

Install the two nuts securing the cover to the frame.

ACCESSING THE DRIVE UNIT COMPARTMENT The drive unit compartment is concealed behind a molded cover which fits securely around the drive unit and steer support to the frame.

1. DRIVE UNIT COMPARTMENT COVER 2. ALIGNMENT PIN

Remove the drive unit cover, starting at the top left edge of the cover and with both hands pull the cover away from the frame until the cover kicks out from the retaining clips. Repeat this for the right side of the cover. Work around the edge of the cover until free from the truck. See Figure 2.

To install the drive unit cover, place the bottom of the drive unit cover onto the frame and position the lower edges partially into the lower retaining clips.

Align the holes in the cover with the alignment pin attached to the frame. Push the top of the cover partially into the upper retaining clips. Do not push either edge of the cover in completely in before starting all edges into the proper place. When the cover is aligned and started properly, press the cover completely into the retaining clips.

3. RETAINING CLIPS 4. FRAME

Figure 2. Drive Unit Compartment Cover A419

2

0620 SRM 1513

Special Precautions

Special Precautions DISCHARGING THE CAPACITORS WARNING The capacitor in the transistor controller can hold an electrical charge after the battery is disconnected. To prevent electrical shock and personal injury, discharge the capacitor before inspecting or repairing any component. Wear safety glasses.

Make certain the battery has been disconnected.

DO NOT use a screwdriver to discharge the traction motor controller.

WARNING To avoid personal injury and prevent electrical shock, perform the following steps before performing any troubleshooting or adjustments, and connecting or disconnecting a handset or PC.

CAUTION To avoid controller damage, always disconnect the battery. Discharge the capacitor and never put power to the controller with any power wire disconnected. Never short any controller terminal or motor terminal to battery. Make sure to use proper procedures when servicing the controller.

1. Turn the key switch to the OFF position and disconnect the battery.

2. Remove the drive unit compartment cover to access the controller. See GeneralGeneralGeneral.

3. Discharge the capacitors in the controllers by connecting a 200-ohm, 2-watt resistor across the controller's B+ and B− terminals using insulated jumper wires. See Figure 3. DO NOT short across the motor controller terminals with a screwdriver or jumper wire. Remove the 200-ohm, 2-watt resistor before reconnecting the battery.

1.

2.

3.

4.

5.

CONTROLLER POSITIVE CONNECTION INSULATED JUMPER WIRES 200-OHM, 2-WATT RESISTOR NEGATIVE CONNECTION Figure 3. Discharging the Capacitors

3

Description

0620 SRM 1513

Description The traction motor is a three-phase AC induction motor. DC battery current is converted into AC current in the controller and then supplied to the traction motor. The controller controls motor speed and direction. Each traction motor contains an encoder bearing in the flange (brake end) that provides continuous motor speed and direction information to the controller. A temperature sensor built into the stator continually monitors motor temperature.

Brass terminals receive the power cables from the controller and a small connector links the encoder

bearing wiring harness to the main wiring harness.

A shaft extends out the top and bottom of the traction motor. The splined end of the shaft engages the input gear in the drive unit. A short, round section of the shaft protrudes from the top of the motor and is secured in place with a snap ring which secures it to the flange. This end also supports the parking brake hub using a woodruff key and two additional small snap rings.

AC Motor Repair REMOVE WARNING The AC traction motor is heavy. To prevent injury, use a lifting device of adequate capacity for lifting the assembly.

It is not necessary to remove the traction motor from the lift truck to make some repairs. Perform only the steps necessary to safely complete the required service.

1. Turn the key switch to the OFF position and disconnect the battery connector. Discharge the capacitors. See Special Precautions.

2. Remove the steer support from the lift truck.

Refer to Steering Mechanism 1600SRM1504.

CAUTION Remove the brake only as directed. Changes to adjustment screws may render the brake unusable. The brake is factory set and cannot be adjusted if altered.

NOTE: The brake may be removed at this point.

However, it is not necessary to remove the brake if the motor will not be disassembled.

3. Remove the brake from the top of the traction motor if necessary. See Brakes 1800SRM1505.

4. Identify, tag, and disconnect power cables and wiring connecting traction motor to the truck electrical system.

4

5. Remove the four capscrews and lockwashers holding traction motor to the drive unit.

6. Attach a sling and a lifting device to the traction motor. Lift the motor from the drive unit and position it securely at a suitable work station. Remove the sling from the motor.

DISASSEMBLE Some disassembly may be performed with the traction motor installed in the lift truck. Perform only the steps necessary to safely complete the required service.

1. If the traction motor is not to be removed from the lift truck, remove the steer support from the lift truck. Refer to Steering Mechanism 1600SRM1504.

2. Remove the brake and hub assembly and both the upper and lower snap rings from the motor shaft if installed.

Refer to Brakes 1800SRM1505.

3. Remove the four long screws holding the traction motor together.

4. Remove the snap ring from the shaft securing the flange (brake end) to the shaft. Slide the flange (brake end) off the shaft and remove from the top of the motor.

5. Remove the armature from the stator if necessary.

6. Separate the stator from the bottom flange (drive end) if necessary.

0620 SRM 1513

1.

2.

3.

4.

5.

6.

7.

8.

9.

AC Motor Repair

ENCODER CONNECTOR (FEMALE 4 PRONG) ARMATURE SNAP RING SNAP RINGS (BRAKE ASSEMBLY) LOCKWASHER ASSEMBLY SCREW STATOR NUTS LOCKWASHER

10. TEMP SENSOR CONNECTOR (FEMALE 2 PRONG) 11. MOUNTING PLATE ASSEMBLY 12. SCREW 13. GROMMET 14. FLANGE (BRAKE END) 15. FLANGE HOUSING 16. BEARING AND WIRING

Figure 4. Traction Motor Repair

5

AC Motor Repair

0620 SRM 1513

Figure 5. Traction Motor Repair (A419)

6

0620 SRM 1513

AC Motor Repair Legend for Figure 5

1.

2.

3.

4.

BRAKE ASSEMBLY MOTOR SNAP RING ASSEMBLY SCREW

INSPECT Inspect the armature and the inside of the stator for marks or grooves indicating contact between the rotor and the motor case. Replace if damaged. Bearings should fit snug where they seat on the shaft. If there is excessive wear, replace the bearing and/or shaft. Check the bearings for smooth operation. If a bearing does not roll smoothly, it must be replaced.

Check that resistance between the windings and the case is above 50,000 ohms. Resistance of the windings (line to line) should be less than 1 ohm.

ASSEMBLE

5.

6.

7.

8.

SPEED SENSOR O-RING WOODRUFF KEY NUT

5. Align the motor flanges and install the four assembly screws.

6. Install the brake to the top of the traction motor. Refer to Brakes 1800SRM1505.

7. Install the steering support to the lift truck, if removed. Refer to Steering Mechanism 1600SRM1504.

INSTALL 1. Apply Molykote® G-N paste to the splines of the traction motor lower shaft.

Partial disassembly may be have been performed with the traction motor installed in the lift truck.

Assemble the motor directly into the lift truck if only partially disassembled. Perform only the steps necessary to safely complete the required service.

2. Attach a sling and a lifting device to the traction motor. Lift the motor from the work station and position it above the drive unit. Slowly lower the motor while turning to align the spines of the motor shaft with the drive unit.

Remove the sling from the motor.

1. Install the long screws to the flange (drive end).

If assembling directly into the lift truck, position the stator to drive unit as removed.

3. Turn the motor to align the motor mount brackets with the mounting holes of the drive unit.

Install the four screws to secure the motor.

2. Align the stator to the lower flange as removed.

4. Install the brake to the top of the traction motor. Refer to Brakes 1800SRM1505.

3. Install the armature down through the top of the stator and carefully guide it through the stator. If assembling directly into the drive unit, apply Molykote® G-N paste to the splines of the lower shaft and install into the drive unit. Slowly lower the armature through the stator while turning to align the spines of the shaft with the drive unit.

4. Position the flange (brake end) onto the armature shaft and stator as removed. Be careful not to damage the encoder bearing wiring harness during installation.

5. Route and connect all wiring and connectors as removed.

6. Install the steering support and dash assembly to the lift truck. Refer to Steering Mechanism 1600SRM1504.

7. Connect the battery connector, turn the key switch to the ON position, and test the lift truck for proper operation. Remove the lift truck from blocks and return to service.

7

Troubleshooting

0620 SRM 1513

Troubleshooting PROBLEM Unusual noise from traction motor.

POSSIBLE CAUSE Parking brake damaged.

not

releasing/

PROCEDURE OR ACTION Troubleshoot the parking brakes.

Drive unit internal damage.

Check that the drive unit rotates smoothly.

Traction motor bearing damaged.

Replace end head(s) and check stator and rotor for damage. Replace damaged components or traction motor if necessary.

Encoder broken.

Replace encoder bearing.

Encoder wire broken.

Check and repair encoder wire or replace encoder bearing.

Temperature sensor wire damaged.

Measure resistance with ohmmeter. Resistance should be 530 ohms at 25 °C (77 °F). Inspect and repair temperature sensor wire. The temperature sensor wire can be repaired, but the temperature sensor must be replaced if faulty.

Main wiring harness damaged.

Test temperature sensor circuit through main wiring harness from connection at controller.

Temperature sensor malfunction.

Measure resistance with ohmmeter. If wiring is ok, resistance should be 530 ohms at 25 °C (77 °F). Replace the temperature sensor.

Stator shorting.

Loss of insulation in wire.

Disconnect the battery and check resistance between winding and case. Resistance should be at 50,000 ohms or above.

Stator open circuit.

Broken coil windings.

Raise drive wheel off the floor and verify voltage at motor terminals. Disconnect the battery and check resistance of windings.

Truck moves slow or in a jerky motion.

Temperature sensor failure.

8

0620 SRM 1513

PROBLEM Traction motor does not operate.

Troubleshooting

POSSIBLE CAUSE

PROCEDURE OR ACTION

Battery lacks sufficient charge.

Charge/change battery.

Throttle position sensor or neutral switch broken or out of adjustment.

Troubleshoot the throttle position sensor or neutral switch.

Stator coil shorted to case.

Check resistance between winding and case. Resistance should be at 50,000 ohms or above. Replace stator or traction motor assembly if necessary.

Stator wires broken-open circuit.

Check resistance between motor terminals. Resistance should read less than 1 ohm between each terminal. Replace stator or traction motor assembly if necessary.

Electric brake assembly not releasing/damaged.

Troubleshoot the electric brake assembly.

Drive unit internal damage.

Raise the drive tire and check that the drive unit rotates smoothly.

9

NOTES

10

TECHNICAL PUBLICATIONS 0620 SRM 1513

3/15 (12/13)(6/11)

BRAKES P2.0 [A290]; W45ZHD [A419]

PART NO. 4035862

1800 SRM 1505

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR •

• • • • • • • • • • • • • •

The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the product. Updated technical service information may be available from your local authorized Hyster® dealer. Service Manuals provide general guidelines for maintenance and service and are intended for use by trained and experienced technicians. Failure to properly maintain equipment or to follow instructions contained in the Service Manual could result in damage to the products, personal injury, property damage or death.

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 when making 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.

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury and property damage.

On the lift truck, the WARNING symbol and word are on orange background. The CAUTION symbol and word are on yellow background.

Table of Contents

TABLE OF CONTENTS General .....................................................................................................................................................................1 Description ...............................................................................................................................................................1 Special Precautions ................................................................................................................................................. 2 Brake Check ............................................................................................................................................................ 4 Hold On Grade Test ............................................................................................................................................ 4 Brake Coil Check .....................................................................................................................................................4 Brake Assembly Repair ...........................................................................................................................................4 Remove ................................................................................................................................................................ 4 Install ...................................................................................................................................................................5 Troubleshooting .......................................................................................................................................................6 This section is for the following models: P2.0 [A290]; (W45ZHD) [A419]

©2015 HYSTER COMPANY

i

"THE QUALITY KEEPERS" HYSTER APPROVED PARTS

1800 SRM 1505

General

General WARNING DO NOT operate a lift truck that needs repairs. If a repair is necessary, put a DO NOT OPERATE tag on the control handle. Remove the key from the key switch.

WARNING Before performing repairs or adjustments on the brake system, blocks must be placed under each side of the frame to raise the drive tire off the ground. The blocks must prevent the lift truck from falling and causing personal injury or property damage. See Periodic Maintenance

8000SRM1510 or Periodic Maintenance 8000SRM1666 - How To Put A Lift Truck On Blocks.

WARNING Always disconnect and separate the battery connector so that the connector is completely free before performing any service or repairs. If the connector is not completely free, it can reconnect. Tag the connector: DO NOT CONNECT. This section describes the electric brake and outlines the procedures for the maintenance and repair that may be required for servicing this truck.

Description Motorized hand trucks have three methods of braking: 1. Regenerative (Neutral) braking 2. Controlled plugging 3. Application of the spring-applied, electrically-released friction brake NOTE: The preferred method of stopping the truck is: Regenerative (Neutral) braking or Controlled plugging Regenerative (Neutral) braking applies a retarding force to the drive wheel through the traction motor, allowing the unit to slow to a gradual stop. It is applied by returning the speed/direction control to the NEUTRAL position.

Controlled plugging is reversing the speed/direction control while traveling, causing the unit to slow to a stop. Return the speed/direction control to the NEUTRAL position to remain stopped. If the speed/direction control is not returned to the NEUTRAL position, the lift truck will accelerate in the

opposite direction. Controlled plugging should stop the truck within one to one and a half truck lengths, depending on speed and load.

The brake is designed to hold the truck loaded to capacity on a 10% grade. The lift truck should be tested periodically to ensure that the brake is performing to the proper specifications. See Brake Check in this section for testing instructions. If the brake does not release or fails to perform to the necessary requirements, the brake assembly must be repaired or replaced. Refer to Brake Assembly Repair in this section for procedures to repair or replace the brake.

A spring-applied, electrically released friction brake is mounted to the drive motor. When the brake is applied, springs inside the brake assembly compress a rotating friction disk against two stationary plates. When the brake is released, the brake coil will energize and pull the armature plate away from the friction disk, releasing the brake as the drive motor is activated.

The brake is applied when the control handle arm is moved to the BRAKE ON position, when the truck is idle for periods of time, or if there is a traction fault.

1

Description

1800 SRM 1505

To release the brake: 1. Connect the battery.

2. Turn the key switch to the ON position.

3. Lower the control handle arm to the operating or BRAKE OFF position. Refer to Figure 1.

4. Rotate direction/speed control (butterfly knobs) in the direction of travel.

The friction brake is applied when the key switch is in the OFF position on ALL trucks.

NOTE: If the battery state of charge is too low, or if there is damage to the brake, MDU, or electrical system, then it may not be possible to move the lift truck before servicing the truck.

A. BRAKE ON B. BRAKE OFF C. BRAKE ON Figure 1. Brake Operation

Special Precautions WARNING Put blocks under each side of the truck under the drive unit frame. Position blocks on both sides of the load wheels. The blocks must prevent the lift truck from falling and causing personal injury or property damage.

The capacitor in the transistor controller can hold an electrical charge after the battery is disconnected. To prevent electrical shock and personal injury, discharge the capacitor before inspecting or repairing any component. Wear safety glasses.

Make certain the battery has been disconnected.

Discharge the capacitors in the controller by connecting a 200-ohm, 2-watt resistor across the controller's B+ and B- terminals with insulated jumper wires. DO NOT use a screwdriver to discharge the traction motor controller.

To avoid personal injury and prevent electrical shock, perform the following steps before performing any troubleshooting or adjustments, and connecting or disconnecting a handset or PC.

2

CAUTION To avoid controller damage, always disconnect the battery. Discharge the capacitor and never put power to the controller with any power wire disconnected. Never short any controller terminal or motor terminal to battery. Make sure to use proper procedures when servicing the controller.

1. Block the lift truck so the drive wheel is off the floor.

See Periodic Maintenance 8000SRM1510 or Periodic Maintenance 8000SRM1666 - How to Put a Lift Truck on Blocks.

2. Turn the key switch to the OFF position and disconnect the battery.

1800 SRM 1505

Special Precautions

3. Discharge the capacitors in the controllers by connecting a 200-ohm, 2-watt resistor across the controller's B+ and B- terminals. See Figure 2. DO NOT short across the motor controller terminals with a screwdriver or jumper wire. Remove the 200-ohm, 2-watt resistor before reconnecting the battery.

1.

2.

3.

4.

5.

CONTROLLER POSITIVE CONNECTION INSULATED JUMPER WIRES 200-OHM, 2-WATT RESISTOR NEGATIVE CONNECTION Figure 2. Discharging Controller

3

Brake Check

1800 SRM 1505

Brake Check HOLD ON GRADE TEST WARNING DO NOT stand below or ride on the lift truck when performing the hold on grade test.

The brake should be checked for hold capacity every 2000 hours or yearly or any time substandard brake performance is suspected. Load a stable, fullcapacity load on the forks and position the lift truck at the base of a 10-percent grade (1.0 m rise in 10.0 m (3 ft rise in 30 ft)) grade with the forks facing uphill. Standing to the side of the lift truck, slowly drive the lift truck up the grade and bring the lift truck to a stop using the directional controls (plugging). Move the control handle to the BRAKE ON position to apply the parking brake. See Figure 3. If the brake fails to hold the lift truck on the grade, the brake assembly must be repaired or replaced. For instructions on repairing or replacing the brake, refer to Brake Assembly Repair in this section.

1. CAPACITY LOAD 2. 10% GRADE 3. FORKS UPHILL Figure 3. Hold On Grade Test

Brake Coil Check Check for correct brake coil resistance. The brake coil can be checked with a ohmmeter. The coil resistance should be the value shown in Table 1.

Table 1. Brake Coil Resistance Model Number

Resistance (±10%)

P2.0, W45ZHD

22.75 ohms

Brake Assembly Repair REMOVE CAUTION The brake is not adjustable. Be careful not to alter the position standoff bolts during repairs.

Some parts of the steering control handle must be disconnected to disassemble the brakes. For additional information about removal and installation of the steering control handle, see section Steering Mechanism 1600SRM1504.

1. Move the truck to a safe, level area. Turn the key switch to the OFF position and disconnect the battery.

4

Block the wheels to prevent unexpected movement. See: •

Periodic Maintenance 8000SRM1510 for lift truck model A290

•

Periodic Maintenance 8000SRM1666 for lift truck model A419

2. Remove the drive unit compartment cover. Refer to AC Motor Repair 0620SRM1513.

3. Disconnect the brake wiring connector from the main wiring harness connector.

4. Remove the three capscrews that hold the brake assembly to the motor and remove the brake. See Figure 4.

1800 SRM 1505 5. Remove the screws holding the adapter to the magnet body and remove the adapter and the friction disk.

WARNING Use caution when removing or installing snap rings. These snap rings can come loose during removal or installation with enough force to cause personal injury. Always use the correct snap ring pliers and wear eye and face protection during removal and installation.

6. Remove the snap ring from the top of the traction motor shaft securing the brake hub in place.

7. Slide the brake hub up off the traction motor shaft. Recover the Woodruff key. Remove the lower snap ring if necessary.

Brake Assembly Repair

INSTALL WARNING Use caution when removing or installing snap rings. These snap rings can come loose during removal or installation with enough force to cause personal injury. Always use the correct snap ring pliers and wear eye and face protection during removal and installation.

1. Install lower snap ring if removed.

2. Position the Woodruff key into the groove on the traction motor shaft as removed.

3. Align the Woodruff key with the groove inside the brake hub. Slide the brake hub down onto the traction motor shaft and Woodruff key.

4. Install the upper snap ring on the end of the motor shaft.

5. Replace the adapter and friction disk and tighten the screws that hold the adapter to the brake. Torque to 11 N•m (8 lbf ft).

6. Replace the brake and install the lockwashers and capscrews that hold the brake to the motor.

7. Tighten the capscrews. Torque to 12 to 14 N•m (8.8 to 10.3 lbf ft).

8. Connect the brake wiring connector to the main wiring harness.

9. Check the brake switch at the control handle base for operation and to ensure that the wires are connected and that there is no obstruction of movement.

10. Install the drive unit compartment cover. Refer to AC Motor Repair 0620SRM1513.

11. Remove the blocks. Connect the battery and test the operation of the lift truck prior to returning the lift truck to service.

1.

2.

3.

4.

5.

6.

7.

8.

BRAKE ASSEMBLY CAPSCREW UPPER SNAP RING BRAKE HUB LOWER SNAP RING TRACTION MOTOR WOODRUFF KEY MOTOR SHAFT

NOTE: The brake must hold the lift truck with a maximum rated load on a 10 percent grade (0.305 m (1 ft) rise in 3.05 m (10 ft)).

The truck should operate without any drag when the handle is in the operating position.

Figure 4. Brake Assembly

5

Troubleshooting

1800 SRM 1505

Troubleshooting PROBLEM Brake does not release.

Brake does not hold truck loaded to capacity on 10% grade.

6

POSSIBLE CAUSE

PROCEDURE OR ACTION

Key switch is in the OFF position.

Turn key switch to the ON position.

Battery is not connected or properly charged.

Connect or clean battery connections. Charge if necessary.

Handle is not in the BRAKE OFF position.

Move the handle to the BRAKE OFF position.

Control handle arm prox switch is out of adjustment/damaged.

Adjust/replace control handle arm prox switch. See the section Electrical System 2200SRM1508.

Brake coil open circuit.

Measure coil resistance. Refer to Brake Check in this section. If resistance is above specification, replace the brake assembly.

Brake coil has shorted to frame or between the windings.

Measure coil resistance. Refer to Brake Check in this section. If resistance is below specification, replace the brake assembly.

Check coil for short to frame using an ohmmeter. If shorted to frame, replace the brake assembly.

Incorrect or no voltage supplied to brake.

Measure voltage to brake using a voltmeter. If voltage is not 24 VDC ±10%, troubleshoot brake wiring. Troubleshoot electrical system and controller.

Debris pollution of residual gap.

Clean air gap. Ensure that residual gap returns to 0-0.06mm.

Air gap is too large.

Replace the brake assembly.

Friction disk is too worn.

Replace the brake assembly.

Brake hub damaged.

Replace brake and hub assembly.

1800 SRM 1505

PROBLEM Brake will not apply.

Troubleshooting

POSSIBLE CAUSE

PROCEDURE OR ACTION

Mechanical failure within the brake assembly.

Replace the brake assembly.

Brake linings worn beyond specification. See Brake Check in this section.

Replace the brake assembly.

7

NOTES

8

TECHNICAL PUBLICATIONS 1800 SRM 1505

3/15 (12/13)(6/11)

CONTROLLER DIAGNOSTICS W45ZHD [A419]

PART NO. 4101970

9000 SRM 1671

SAFETY PRECAUTIONS TROUBLESHOOTING PROCEDURES •

•

• • • • • • • • • • • •

•

The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the product. Updated technical service information may be available from your local authorized Hyster® dealer.

Service Manuals provide general guidelines for maintenance and service and are intended for use by trained and experienced technicians. Failure to properly maintain equipment or to follow instructions contained in the Service Manual could result in damage to the products, personal injury, property damage or death.

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 when making 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.

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a condition that can cause immediate death or injury!

CAUTION Indicates a condition that can cause property damage!

On the lift truck, the WARNING symbol and word are on orange background. The CAUTION symbol and word are on yellow background.

CONTROLLER DIAGNOSTICS

Table of Contents

TABLE OF CONTENTS SECTION 9030 - ELECTRICAL SYSTEM Group 03 - General Maintenance and Diagnostic Data.....................................................................9030-03-1 Group 20 - Diagnostic Trouble Codes............................................................................................... 9030-20-1 This section is for the following models: (W45ZHD) [A419]

©2015 HYSTER COMPANY

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How To Use This Troubleshooting Manual

CONTROLLER DIAGNOSTICS

How To Use This Troubleshooting Manual GENERAL INSTRUCTIONS AND SAFETY INFORMATION WARNING

Groups: The 9030 Electrical System is divided into two groups that identify specific electrical troubleshooting procedures.

•

03 – General Maintenance/Diagnostic Data The General Maintenance and Diagnostic Data group includes general troubleshooting, discharging the capacitors, basic electrical troubleshooting, multiplexing, User Iterface, and status codes and descriptions.

•

20 – Diagnostic Trouble Codes The Diagnostic Trouble Codes group includes all troubleshooting procedures for status codes reported by a given Node or system.

DO NOT add to or modify the lift truck. Any modification that affects the safe operation of the truck cannot be undertaken without written authorization of the Hyster company.

Any change to the lift truck, the tires, or its equipment can change the lifting capacity. The lift truck must be rated as equipped and the nameplate must show the new rating capacity.

WARNING The technician must be aware of, and follow, all general safety precautions that are published in the Operating Manual and that are posted as Safety Decals on and in the lift truck.

Before starting, the technician should be familiar with certain policies, requirements, and instructions used in the troubleshooting procedures. Using the troubleshooting procedures correctly helps the technician to perform the procedure safely and prevents damage to the machine and support equipment.

HOW TO USE DIAGNOSTIC TROUBLESHOOTING MANUAL Manual Layout: Section: This manual consists of one section which is further divided into groups.

•

9030 – Electrical System

For a listing of all Diagnostic Trouble Codes and descriptions, see the section of this manual.

GENERAL INSTRUCTIONS 1. Become familiar with the content, layout, and access provisions of data in this manual. This will improve your efficiency and decrease the time required to resolve the problems.

2. Once you begin a troubleshooting procedure, do not skip steps.

3. If you reach the end of a procedure without resolving the problem and you are not directed to another procedure contact Resident Service Engineering through the Contact Management System.

4. Do not limit yourself, remember to apply your own experience and knowledge to assist in resolving the problems, but do not compromise safety in doing so.

5. Most of the cross-reference data in the manual will be electronically linked for rapid and easy access. Use the links wherever the cursor highlights an item as a linkable option.

Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams

ii

SECTION 9030

ELECTRICAL SYSTEM TABLE OF CONTENTS Group 03 - General Maintenance and Diagnostic Data General Troubleshooting.................................................................................................................... 9030-03-1 Discharging the Capacitors.................................................................................................................9030-03-2 Electrical Test Equipment................................................................................................................... 9030-03-3 PC Service Tool..............................................................................................................................9030-03-3 Digital Multimeter (DMM)................................................................................................................9030-03-3 Jumper Wires, Test Leads, and Test Lights................................................................................... 9030-03-3 Basic Electrical Troubleshooting............................................................................................................. 9030-03-4 Electrical Checks................................................................................................................................ 9030-03-4 Voltage Checks.............................................................................................................................. 9030-03-4 Amperage Checks..........................................................................................................................9030-03-5 Resistance Checks.........................................................................................................................9030-03-5 Contactor and Contactor Coil Checks............................................................................................ 9030-03-5 Lift and Lower Switch Check.......................................................................................................... 9030-03-6 Multiplexing............................................................................................................................................. 9030-03-7 Multiplexing and the CANbus............................................................................................................. 9030-03-7 Troubleshooting the CANbus......................................................................................................... 9030-03-7 Troubleshooting the Tiller Control Card Termination Resistor....................................................... 9030-03-8 Troubleshooting the Traction Controller Termination Resistor....................................................... 9030-03-8 User Interface..........................................................................................................................................9030-03-8 User Interface, Setup, and Troubleshooting....................................................................................... 9030-03-8 Parameters......................................................................................................................................... 9030-03-8 Status Code Indication................................................................................................................... 9030-03-8 Speed Steering Reduction..............................................................................................................9030-03-8 Traction Steering Decel Ramp....................................................................................................... 9030-03-8 Response-Full Accel Rate HS........................................................................................................ 9030-03-8 Response-Full Accel Rate LS.........................................................................................................9030-03-9 Response-Low Accel Rate............................................................................................................. 9030-03-9 Response-Neutral Decel Rate HS..................................................................................................9030-03-9 Response-Neutral Decel Rate LS.................................................................................................. 9030-03-9 Fine Tuning-Partial Decel Rate...................................................................................................... 9030-03-9 Fine Tuning-HS (High Speed)........................................................................................................ 9030-03-9 Fine Tuning-LS (Low Speed)..........................................................................................................9030-03-9 Fine Tuning-Reversal Soften..........................................................................................................9030-03-9 Fine Tuning-Max Speed Accel..................................................................................................... 9030-03-10 Fine Tuning-Max Speed Decel.....................................................................................................9030-03-10 Interlock Timeout..........................................................................................................................9030-03-10 Mode (1 through 3) -Max Speed...................................................................................................9030-03-10 Mode (1 through 3) -Max Accel.................................................................................................... 9030-03-10 Mode (1 through 3) -Walk Accel................................................................................................... 9030-03-10 Mode (1 through 3) -Max Decel....................................................................................................9030-03-10 Mode (1 through 3) -Neutral Braking............................................................................................ 9030-03-10 Mode (1 through 3) -Max Braking.................................................................................................9030-03-10 Max Speed TM2........................................................................................................................... 9030-03-10 Max Accel TM2.............................................................................................................................9030-03-10

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9030-1

Max Decel TM2............................................................................................................................ 9030-03-10 Neutral Braking TM2.....................................................................................................................9030-03-10 Max Braking TM2......................................................................................................................... 9030-03-10 Turtle Alarm enable...................................................................................................................... 9030-03-11 Quick Lift Window.........................................................................................................................9030-03-11 Initial Lift Interval...........................................................................................................................9030-03-11 Full Lift Interval............................................................................................................................. 9030-03-11 Lift Run Time................................................................................................................................ 9030-03-11 BDI Warning (Lift Lock) Enable.................................................................................................... 9030-03-11 Warning BDI (Lift Lock Out Percent)............................................................................................ 9030-03-11 Battery-BDI Reset Volts................................................................................................................9030-03-11 Battery- BDI Full Volts.................................................................................................................. 9030-03-11 Battery-BDI Empty Volts...............................................................................................................9030-03-11 Battery-BDI Discharge Time.........................................................................................................9030-03-11 Battery-BDI Reset Percent........................................................................................................... 9030-03-12 Undervoltage Cutback Range...................................................................................................... 9030-03-12 User Undervoltage .......................................................................................................................9030-03-12 Total Maintenance Enable............................................................................................................9030-03-12 Traction Maintenance Enable.......................................................................................................9030-03-12 Pump Maintenance Enable.......................................................................................................... 9030-03-12 Maintenance Interval.................................................................................................................... 9030-03-12 Reset Total Maintenance..............................................................................................................9030-03-12 Reset Traction Maintenance.........................................................................................................9030-03-12 Reset Pump Maintenance............................................................................................................ 9030-03-12 Status Codes and Descriptions.............................................................................................................9030-03-13 Status Codes.................................................................................................................................... 9030-03-13 Status Code Descriptions................................................................................................................. 9030-03-13 Group 20 - Diagnostic Trouble Codes DTC 30001 - LiftCoil................................................................................................................................9030-20-2 DTC 30003 - LwrCoil...............................................................................................................................9030-20-5 DTC 30033 - Main Cont.......................................................................................................................... 9030-20-8 DTC 30035 - Brake............................................................................................................................... 9030-20-11 DTC 30037 - AlrmCoil........................................................................................................................... 9030-20-15 DTC 30039 - Audible Alarm (Opt)......................................................................................................... 9030-20-18 DTC 30060 - Mtr Curr........................................................................................................................... 9030-20-20 DTC 30061 - Mtr Open .........................................................................................................................9030-20-20 DTC 30062 - Encoder........................................................................................................................... 9030-20-22 DTC 30067 - MainCont (Stuck Closed).................................................................................................9030-20-25 DTC 30068 - MainCont (Stuck Open)................................................................................................... 9030-20-29 DTC 30069 - Precharge........................................................................................................................ 9030-20-33 DTC 30080 - OverHeat......................................................................................................................... 9030-20-36 DTC 30086 - LowBatt............................................................................................................................9030-20-38 DTC 30087 - OverVolt...........................................................................................................................9030-20-41 DTC 30090 - 12 Vdc / 5 Vdc Supply Output......................................................................................... 9030-20-44 DTC 30106 - CANcomm....................................................................................................................... 9030-20-47 DTC 30201 - Start Up........................................................................................................................... 9030-20-50 DTC 60211 - Start Up........................................................................................................................... 9030-20-50 DTC 30227 - Stalled .............................................................................................................................9030-20-55 DTC 30232 - Software ......................................................................................................................... 9030-20-58 DTC 30247 - Parameter........................................................................................................................9030-20-59 DTC 30248 - Low Temp........................................................................................................................9030-20-60 DTC 60050 - EmerRevr........................................................................................................................ 9030-20-62 DTC 60210 - EmerRevr........................................................................................................................ 9030-20-62

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9030-2

ELECTRICAL SYSTEM

General Maintenance and Diagnostic Data

Group 03

General Maintenance and Diagnostic Data GENERAL TROUBLESHOOTING In the event the lift truck does not operate correctly, a status code is displayed on the display panel. Once the status code is obtained, follow the procedures outlined in this manual only after reviewing the following information regarding the truck’s unique electrical system and troubleshooting procedures.

NOTE: Due to the interaction of the traction controller with all truck functions, almost any status code or controller fault could be caused by an internal failure of the traction controller. After all other status code procedures have been followed and no problem is found, the traction controller should be tested and replaced as the last option to correct the problem.

Prior to troubleshooting systems and components on the vehicle, ensure the battery voltage is correct and within specifications. Make sure the battery connector contacts are clean of corrosion and the battery polarity within the connector is correct. Inspect that all fuses are correct and are not the cause of component failure. Ensure the key switch is in the ON position when conducting voltage checks or verifying the operation of a component. Make sure the brake switch is functioning properly and is closed.

Many faults noted by lift truck’s electrical system may be the result of loose wiring connections and/or broken or shorted wiring within the lift truck. Begin the troubleshooting process by carefully inspecting the wiring involving the device or devices noted by the onboard diagnostic system. .

The controllers are sealed units with no serviceable components. Troubleshooting is usually limited to accessing status codes and following the diagnostic procedure provided for each status code.

Use standard testing procedures to verify inputs and outputs when necessary.

CAUTION Never attempt to probe through the back of the connector plugs of the motor controller. These plugs are special sealed plugs. Probing through the back of the plugs will destroy the seal and can cause a short circuit. If a circuit must be tested for voltage, check for voltage at an amp-type plug, a switch, or component. If a circuit is suspect, check the circuit for continuity by disconnecting the plug and testing continuity from the front (pin end) of the plug.

Standard probes are too large to be inserted into the center of female pins (sockets) of the special sealed plugs and can damage or expand the pins.

Expanded pins will not provide good connections once the plug is reconnected. The connectors are shaped to allow the insertion of a small flat-blade screwdriver into the connector. After inserting the screwdriver into the connector, attach probes with alligator clips to the shank of the screwdriver to obtain readings.

Refer to 8000 SRM 1512 for wiring diagrams and additional circuit information.

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9030-03-1

General Maintenance and Diagnostic Data

DISCHARGING THE CAPACITORS When working with the electrical systems of the truck, it is necessary to discharge the internal or external capacitors of the controllers associated with each circuit affected.

ELECTRICAL SYSTEM To prevent an electrical shock and personal injury, discharge the internal or external capacitors before inspecting or repairing any component in the electrical compartments. Make certain that the battery has been disconnected.

DO NOT short across the motor controller terminals with a screwdriver or jumper wire.

WARNING DO NOT make repairs or adjustments unless you have been properly trained and authorized to do so. Improper repairs and adjustments can create dangerous operating conditions. DO NOT operate a lift truck that needs repairs. Report the need for repairs to your supervisor immediately. If repair is necessary, attach a DO NOT OPERATE tag to the control handle and disconnect the battery.

Disconnect the battery and discharge the internal or external capacitors before opening any compartment covers or inspecting or repairing the electrical system. DO NOT place tools on top of the battery. If a tool causes a short circuit, the high current flow from the battery can cause personal injury or property damage.

Some checks and adjustments are performed with the battery connected. DO NOT connect the battery until the procedure instructs you to do so.

Never wear jewelry or other metallic items on your fingers, arms, or neck when working near electrical components. Metal items can accidentally make an electrical connection and cause injury.

Before performing any tests or adjustments, block the lift truck to prevent unexpected movement.

The capacitors in the transistor controllers can hold an electrical charge after the battery is disconnected.

CAUTION To avoid controller damage, always disconnect the battery, discharge the internal or external capacitors, and never put power to the controller while any power wires are disconnected. Never short any controller terminal or motor terminal to the battery. Make sure to use proper procedure when servicing the controller.

1. Move the lift truck to a safe, level area and completely lower the forks. Turn the key switch to the OFF position and attach a DO NOT OPERATE tag to the control handle. Block the drive wheel to prevent unexpected movement.

2. Disconnect the battery power cable connector from the truck connector located on the top-left side of the frame. Pull the battery cable connector handle to separate the battery connector from the truck connector.

3. Remove the operator compartment cover.

4. Discharge the internal or external capacitors in the controllers by connecting a 200-ohm, 2-watt resistor across the controller B(+) and B(-) terminals of the combination controller. Remove the resistor after discharging the capacitors. See Figure 9030-03-1.

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9030-03-2

ELECTRICAL SYSTEM

General Maintenance and Diagnostic Data PC Service Tool The PC Service Tool is a Windows based service application that is used to communicate with the truck’s electrical control system. It can be used to monitor the status and condition of various systems. With this capability, the PC Service Tool can be used to monitor component operation, or determine if abnormal events have occurred in the truck, and assist with diagnostics and troubleshooting.

Digital Multimeter (DMM) Digital multimeters provide several measurement functions in one tool. A DMM should be capable of accurately measuring voltage, amperage, and resistance. Ensure that the multimeter used in troubleshooting procedures is accurate and that the test leads do not have excessive resistance. A faulty meter or damaged test leads will cause inaccurate readings and incorrect electrical diagnoses.

Jumper Wires, Test Leads, and Test Lights When using jumper wires, test leads, and test lights, take care not to force tips into connector sockets. Use appropriate clips and adapters to prevent damage to connectors. Expanded or damaged sockets can cause poor continuity between connections.

1.

2.

3.

4.

5.

TRACTION CONTROLLER POSITIVE CONNECTION INSULATED JUMPER WIRES 200-OHM, 2-WATT RESISTOR NEGATIVE CONNECTION Figure 9030-03-1. Discharging the Capacitors

ELECTRICAL TEST EQUIPMENT Before beginning intrusive circuit checks, verify the vehicle battery state of charge. Visually inspect suspected connectors for loose, damaged, or corroded terminals. Check for blown fuses and inspect circuits for cause of overcurrent conditions. Physically check mechanical operation to ensure a switch, relay, or solenoid is not sticking or damaged.

NOTE: Measuring continuity between two terminals of a switch while operating the switch will determine its functionality.

Jumper wires allow testing across a suspected open in the circuit. Jumper wires can be used for located opens, shorts, and performing voltage drops. If a circuit operates correctly with the jumper wire in place, and is faulty when the jumper wire is removed, a fault can be found in the bypassed location.

Jumper wires can also be used to eliminate sections of the circuit to diagnose either power or grounds. Using the jumper wire to provide a component a known good ground can help reduce the amount of checks needed to diagnose a circuit.

Jumper wires can be used to bypass components such as switches. If a faulty switch is suspected, removing it from the circuit with a jumper wire can determine if a switch or component is at fault.

Jumper wires can be used to check for open or faulty relay contacts which are often sealed and can take additional steps to properly diagnose.

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9030-03-3

General Maintenance and Diagnostic Data Test lights can be used when quick voltage or ground checks are necessary. Many features operate on switched voltage, and using a test light as a load device may be helpful. The test light may also be used to verify continuity to B-. Discretion should be used

ELECTRICAL SYSTEM when troubleshooting a circuit using a test light, as the light may illuminate even though there may be an excessive amount of resistance on the ground circuit or when a low voltage or amperage situation exists.

Basic Electrical Troubleshooting ELECTRICAL CHECKS The following electrical checks are used to diagnose circuit and component faults on trucks. Review the following information so that it may be applied when diagnosing a fault or status code.

Voltage Checks Voltage is electrical pressure or force that pushes current through a circuit. The force is measured in volts.

Low voltage to a load device will cause the device to be inoperative or operate poorly. This can be caused by a low battery source, high circuit resistance, poor connections, or an open circuit; the resistance of poor connections or poor ground acts as an additional load in the circuit, causing low voltage pushing current, or amperage, through a device.

A voltmeter is used to perform:

age as a source of excessive resistance or a poor connection exists, assuming the battery state-ofcharge is correct.

1. Verify battery connectors for loose terminals and appropriate crimping. Measure voltage between terminal before FU1 and B(-).

NOTE: Key in ON position.

Is voltage 24 ± 2.5 Vdc? YES- Proceed to Step 3.

NO- Disconnect battery and proceed to Step 2.

2. Measure resistance between truck frame and each of the following test points: •

Battery postivie wire after FU1

•

B(+) and B(-)

•

Measurement of force

•

U-Phase cable

•

Presence of voltage

•

V-Phase cable

•

Voltage drops

•

W-Phase cable

•

Pump positive cable

•

Pump negative cable

When using a voltmeter to determine if voltage is present and capable of operating a device, connect the positive meter lead to the power circuit of a device’s connector and connect the negative meter lead to the negative battery terminal.

Measuring the voltage drop is performed by connecting the positive test lead to the positive side of the device while simultaneously connecting the negative meter lead to the negative side of the device. The test can also be performed across a section of wire that is faulty and suspected of having excessive resistance.

A voltage drop must be performed while the device is operating. In a circuit with a single load device, the device will drop the total voltage of the circuit. If the device drops less than battery voltage, it can be assumed that the circuits are using the remaining volt-

Is resistance ≥1M ohm?

YES- Charge battery, perform battery maintenance, for non-maintenance free batteries, read battery Specific Gravity level to be within manufacturer specification.

NO- Inspect for all cable insualtion throughout the truck. Inspect battery corrosion around terminals for proper crimping.

3. Measure battery voltage between terminal after FU1 and B(-).

NOTE: Key in ON position.

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9030-03-4

ELECTRICAL SYSTEM Is voltage 24 ± 2.5 Vdc? YES- Proceed to Step 5.

NO-Proceed to Step 4.

4. Measure continuity of Fuse FU1.

Is resistance <1 ohm?

YES- Proceed to Step 5.

NO- Replace Fuse FU1.

5. Ensure battery disconnect switch in UP position, measure voltage between TS04 and B(-).

Is voltage same as battery voltage?

YES- Proceed to Step 6.

NO- Verify TS04 and TS05 terminal connections.

Refer to ELECTRICAL SYSTEM 2200SRM1508 for battery disconnect switch checks.

General Maintenance and Diagnostic Data known as the potential difference. Since amperage is the current in the circuit, increasing voltage also increases the current, or amperage levels.

Measuring amperage is always performed by placing the ammeter in series with the device or circuit. This will cause all current to flow through the protected meter. The circuit must be operating in order to measure amperage. Never measure amperage on high amperage circuits or in parallel to a circuit, this can result in the damage of the meter and the electrical system.

Resistance Checks The ohmmeter is used to measure a circuit or device's resistance in ohms. Ohmmeters use low internal voltage and current which flow through an isolated circuit or device being tested. The voltage of the meter battery and the amount of current flow in the circuit are used to calculate the circuit’s resistance. It is necessary to disconnect or isolate the circuit being test so not to damage the vehicle’s electrical system or the ohmmeter.

6. Measure continuity of Fuse FU2.

Is resistance <1 ohm?

An ohmmeter is used to perform: •

Resistance of a load device

YES- Proceed to Step 7.

•

Resistance of conductors

NO- Replace Fuse FU2.

•

Value of resistors

•

Operation of variable resistors

•

CANbus termination resistors

•

Continuity

7. Measure resistance between key switch terminals TS04 and TS05.

Is resistance <1 ohm?

YES- Inspect CPS 01 socket 1 for appropriate crimping in terminals. Inspect voltage between CPS01 socket 1 and B(-) to be same as battery voltage. If not, inspect circuit 010 for excessive resistance, damage, loose, or open connections.

NO- Inspect key switch terminals to be appropriately connected. If connections are clean and secure and resistance is ≥1 ohm, replace key switch.

Amperage Checks An ammeter is used to measure amperage or current flow through a circuit. An ampere is the measurement of electron flow, which can be used to measure the amount of electrons that are flowing through a circuit.

Ohm’s Law states that current flow in a circuit is equal to the circuit voltage divided by total circuit resistance,

Contactor and Contactor Coil Checks 1. Measure voltage between the coil's positive terminal and B(-).

NOTE: Key in ON position.

Is voltage same as truck's battery voltage?

YES- Proceed to Step 2.

NO- Inspect the Coil's battery B(+) input circuit for open or short.

2. Disconnect coil's ground control circuit. Measure resistance between ground circuit terminal and B(-).

NOTE: Actuate coil ground control to determine if controller is sending activation signal to coil.

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9030-03-5

General Maintenance and Diagnostic Data Is resistance <1 ohm?

YES- Proceed to Step 3.

NO- Inspect ground control circuit. Verify that controller is receiving device input signal.

3. Measure battery voltage between main contactor's battery B(+) terminal and B(-).

NOTE: Key in ON position.

Is voltage same as truck's battery voltage?

YES- Repair or replace faulty contactor.

NO- Inspect main contactor battery cable for loose, damaged, or corroded connections.

Lift and Lower Switch Check 1. Operate lift/lower switch.

Does status code display if truck does not respond to lift and lower command?

ELECTRICAL SYSTEM 3. Measure resistance of tiller card switch JP12, pin 1 and pin 3.

Is resistance 2.7K ohms ± 0.27K ohms YES- Proceed to Step 4.

NO- Replace faulty switch.

4. Measure resistance of tiller card switch JP15, pin 1 and pin 2.

Is resistance 1.4K ohms ± 0.14K ohms YES- Suspect faulty tiller card.

NO- Replace faulty switch.

Lift Function Fault If the lift function is inoperative and no code has been displayed, perform the following troubleshooting procedures: 1. Open tiller head assembly and inspect tiller card.

YES- Proceed to status code description section within this manual to address the status code.

Are lower switches connected to tiller card connectors JP10 and JP14?

NO- Inspect lift and lower switches at tiller head.

YES- Proceed to Step 2.

Lower Function Fault If the lower function is inoperative and no code has been displayed, perform the following troubleshooting procedures:

NO- Connect switches.

2. Disconnect JP10 and connect meter probes at switch connector sockets (blue and black leads) and operate switch.

Is resistance <1 ohm?

1. Open tiller head assembly and inspect tiller card.

Are lower switches connected to tiller card connectors JP12 and JP15?

YES- Proceed to Step 2.

NO- Connect switches.

2. Disconnect JP12 and connect meter probes at switch connector sockets (blue and black leads) and operate switch.

Is resistance <1 ohm?

YES- Proceed to Step 3.

YES- Proceed to Step 3.

NO- Replace faulty switch.

3. Measure resistance of tiller card switch JP10, pin 1 and pin 3.

Is resistance 2.7K ohms ± 0.27K ohms YES- Proceed to Step 4 NO- Replace faulty switch.

4. Measure resistance of tiller card switch JP14, pin 1 and pin 2.

NO- Replace faulty switch.

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9030-03-6

ELECTRICAL SYSTEM

General Maintenance and Diagnostic Data

Is resistance 1.4K ohms ± 0.14K ohms

NO- Replace faulty switch.

YES- Suspect faulty tiller card.

Multiplexing MULTIPLEXING AND THE CANBUS Controller Area Network (CAN) Bus communication allows multiple modules to communicate with each other using the same digital data on a shared network, this method of communication is known as multiplexing. The CANbus is a pair of twisted insulated wires that interconnect all the modules on the network. The data transmitted is a digital encoded format. Digital means only two states are used to transmit data, High/On and Low/Off. This eliminates the need for each module to be hard wired to each sensor. Using Multiplexing, sensor information that may be received by one module, can then be shared with all other modules. The information is sent out over the CANbus in an encoded form and any other module that requires the information can pick it out from the data stream.

The CANbus has two termination resistors (120 ohms) that are connected in parallel. When resistance checks are performed, a normal operating system will display 60 ohms between the CAN LO and CAN HI circuits.

The first 120 ohm termination resistor is located inside the Tiller Control Card. To diagnose, proceed to Troubleshooting the Tiller Control Card Termination Resistor.

The second 120 ohm termination resistor is located in the Traction Controller. To diagnose, proceed to Troubleshooting the Traction Controller Termination Resistor.

Troubleshooting the CANbus

If CAN HI is shorted to B(-) or CAN LO is shorted to battery voltage, network communication will stop.

If you measure battery voltage on the data link, there is a short to power in the circuit.

If you measure 0 volts while the CANBus is active, there is a short to B(-) or an open in the circuit.

Internal control module failures can stop the entire network from communicating. If there are no harness problems, disconnect control modules one at a time until CANbus communication returns.

With both 120 ohm termination resistors connected to the CANbus, resistance between the two circuits should read 60 ohms.

If CANbus resistance is 120 ohms, there is an open circuit or a termination resistor is missing.

If resistance is 0 ohms, the two circuits are shorted together.

1. Measure voltage between the diagnostic connector, socket A and B(-).

NOTE: Key in ON position.

Is voltage approximately 2.5 volts?

YES- Proceed to Step 2.

NO- Inspect CAN HI circuit for open or short; if voltage is 0 volts, the CAN HI circuit is shorted to B(-) or open. If voltage is above 5 volts, the CAN HI is shorted to power.

NOTE: Refer to the latest Diagram SRM for the most current circuit information.

2. Measure voltage between the diagnostic connector, socket B and B(-).

When the CANbus is active and modules are communicating, CAN HI and CAN LO voltage will be approximately 5 volts when added together. If both CAN HI and CAN LO have consistent 2.5 volt, there is no communication on the CANbus.

NOTE: Key in ON position.

Is voltage approximately 2.5 volts?

YES- Disconnect the battery and proceed Step 3.

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9030-03-7

General Maintenance and Diagnostic Data NO- Inspect the CAN LO circuit for open or short; If voltage is 0 volts, the CAN LO circuit is shorted to B(-) or open. If voltage is above 5 volts, the CAN LO is shorted to power.

3. Measure resistance between the diagnostic connector, socket A and socket B. Is resistance 60 ± 6 ohms?

ELECTRICAL SYSTEM 1. Measure resistance between the Tiller Control Card connector CJ2, pin 1 and pin 2.

Is resistance 120 ± 12 ohms?

YES- Reconnect the Tiller Control Card connectors, components, and proceed to Troubleshooting the Traction Controller Termination Resistor.

NO- Replace Tiller Control Card.

YES- CANbus communication is operating correctly.

NO- If resistance is 120 ohms; the CANbus has an open circuit, missing, or damaged termination resistor. If resistance is 0 ohms, the CANbus circuits are shorted together. If resistance is open; the CAN HI and/or CAN LO connection to the diagnostic port may be open. Use the wiring diagrams to detect and correct open circuit.

Troubleshooting the Traction Controller Termination Resistor Disconnect all Traction Controller connectors, cables, and components.

1. Measure resistance between the Traction Controller connector CPS01, pin 21 and pin 34.

Is resistance 120 ± 12 ohms?

Troubleshooting the Tiller Control Card Termination Resistor Disconnect all Tiller Control Card connectors and components.

YES- Reconnect the Traction Controller connectors, cables, components, and proceed to Troubleshooting the CANbus.

NO- Replace Traction Controller.

User Interface USER INTERFACE, SETUP, AND TROUBLESHOOTING The dash display has a LCD screen for displaying truck system information. The dash display also contains a battery state-of-charge indicator.

Status Code Indication This feature indicates if a status code is available. If a status code is present, the fault code number followed by the status code description will be displayed. If other status codes are present, it will display the subsequent status code and description. Two seconds will lapse between display screens before displaying the code sequencing.

PARAMETERS Utilize the User Interface to access and adjust parameters. Not all parameters will be available and will vary between truck applications.

Speed Steering Reduction This optional parameter defines the speed reduction that the motor will target from its current level once the speed reduction sensor changes from ON to OFF. If parameter is set at 75%, and the truck was been driven at 1000 RPM, upon steering the motor will decelerate to 750 RPM. Traction Steering Decel Ramp This optional parameter will determine the time that it will take the motor to decelerate from current speed to speed determined by Speed Steering Reduction parameter. Larger values represent slower response.

Response-Full Accel Rate HS This parameter will set the rate (in seconds) at which the speed command increases when full throttle is applied at high vehicle speeds. Larger values represent slower response. See Figure 9030-03-2 for relationship between Full Accel Rate HS, Full Accel Rate LS, and Low Accel Rate.

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9030-03-8

ELECTRICAL SYSTEM

General Maintenance and Diagnostic Data

Response-Full Accel Rate LS

Fine Tuning-Partial Decel Rate

This parameter sets the rate (in seconds) at which the speed command increases when full throttle is applied at low vehicle speeds.

This parameter sets the rate (in seconds) that is used to slow down the vehicle when the throttle is reduced without being released to neutral. Larger values represent slower response.

Response-Low Accel Rate Fine Tuning-HS (High Speed) This parameter sets the rate (in seconds) at which the speed command increases when a small amount of throttle is applied. This rate is typically adjusted to affect low speed maneuverability.

This parameter sets the percentage of the Typical Max Speed above which the “HS” parameters will be used.

Response-Neutral Decel Rate HS

Fine Tuning-LS (Low Speed)

This parameter sets the rate (in seconds) that is used to slow down the vehicle when the throttle is released to neutral at high vehicle speeds.

This parameter sets the percentage of the Typical Max Speed below which the “LS” parameters will be used.

Response-Neutral Decel Rate LS

Fine Tuning-Reversal Soften

This parameter sets the rate (in seconds) that is used to slow down the vehicle when the throttle is released to neutral at slow vehicle speeds.

This parameter, when set to larger values create a softer reversal from regen braking to drive when near zero speed. The parameter will soften the transition when the regen and drive current limits are set to different values.

NOTE: IN THIS EXAMPLE, HS = 70%, LS = 30%, TYPICAL MAX SPEED = 5000 RPM Figure 9030-03-2. Acceleration Response Rate Diagram

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9030-03-9

General Maintenance and Diagnostic Data

ELECTRICAL SYSTEM

Fine Tuning-Max Speed Accel

Mode (1 through 3) -Max Decel

In some applications, the Max Speed value is changed frequently over the CANbus. The Max Speed Accel parameter controls the rate at which the maximum speed setpoint is allowed to change when the value of Max Speed is raised. The rate set by this parameter is the time to ramp from 0 RPM to Typical Max Speed RPM. If Max Speed is raised from 1000 RPM to 3000 RPM, the Typical Max Speed is 3200 RPM and the rate is 10.0 seconds, it will take 10.0 * (3000–1000) / 3200 = 6.25 seconds to ramp from 1000 RPM to 3000 RPM.

This parameter sets the rate (in seconds) that is used to slow down the vehicle when the throttle is reduced.

Larger values represent slower response.

Fine Tuning-Max Speed Decel

This parameter sets the rate (in seconds) at which the vehicle slows down when full brake is applied or when throttle is applied in the opposite direction.

This parameter is like the Max Speed Accel parameter, except that it controls the rate at which the maximum speed setpoint is allowed to change when the value of Max Speed is lowered. If one changes Max Speed from 300 RPM to 1500 RPM, the Typical Max Speed is 3200 RPM, and the rate is 5.0 seconds, it will take 5.0 * (3000–1500) / 3200 = 2.34 seconds to ramp from 3000 RPM to 1500 RPM.

Mode (1 through 3) -Neutral Braking This parameter adjusts how neutral braking occurs progressively when the throttle is reduced toward the neutral position or when no direction is selected.

Mode (1 through 3) -Max Braking

Max Speed TM2 This parameter defines the maximum requested motor rpm at full throttle when the truck is driven in Advance Turtle mode in region B. See Figure 9030-03-3.

Max Accel TM2

Interlock Timeout This parameter will set the time for which the truck can remain at idle condition while the arm is in operational region B. See Figure 9030-03-3.

This parameter sets the rate (in seconds) at which the motor speed command increases when throttle is applied. This parameter is applicable only while the truck is driven while in Advance Turtle Mode. Larger values represent slower response.

Mode (1 through 3) -Max Speed Max Decel TM2 This parameter defines the maximum requested motor rpm at full throttle.

RPM = VDesired * 936

This parameter sets the rate (in seconds) that is used to slow down the vehicle when the throttle is reduced.

Larger values represent slower response.

Example: RPM = 2.5MPH * 963 = 2340 rpm

Neutral Braking TM2

Mode (1 through 3) -Max Accel This parameter sets the rate (in seconds) at which the motor speed command increases when throttle is applied. Larger values represent slower response.

Neutral braking occurs progressively when the throttle is reduced toward the neutral position or when no direction is selected. This This parameter is applicable only while the truck is driven while in Advance Turtle Mode.

Mode (1 through 3) -Walk Accel

Max Braking TM2

This parameter sets the rate (in seconds) at which the motor speed command increases when throttle is applied, when truck is not in turtle mode. Larger values represent slower response.

This parameter sets the rate (in seconds) at which the vehicle slows down when full brake is applied or when throttle is applied in the opposite direction. This parameter is applicable only while the truck is driven while in Advance Turtle Mode.

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9030-03-10

ELECTRICAL SYSTEM

General Maintenance and Diagnostic Data

Turtle Alarm enable

Battery- BDI Full Volts

This parameter sets an alarm to indicate when the truck has transition from turtle mode (TM1) to turtle mode 2 (TM2). The truck will transition from TM1 to TM2 when the truck is been driven in TM1 and turtle button is depressed while tiller arm transition from operational region A to operational region B. See Figure 9030-03-3.

The full voltage level sets the Keyswitch Voltage that is considered to be state-of-charge; when a loaded battery drops below this voltage, it begins to lose charge. The BDI (battery discharge indicator) algorithm continuously calculates the battery state-ofcharge whenever KSI is on.

Battery-BDI Empty Volts

Quick Lift Window This optional parameter defines the minimum amount of time that the lift button needs to be depressed to activate Quick Lift.

The empty voltage level sets the Keyswitch_Voltage that is considered to 0% state-of-charge when the truck is been used (loaded conditions). The BDI (battery discharge indicator) algorithm continuously calculates the battery state-of-charge whenever KSI is on.

Initial Lift Interval Battery-BDI Discharge Time This optional parameter sets the period of time for which the truck will lift upon Quick Lift command. It shall be enough to lift up the load from the ground so that load wheels can move freely.

Full Lift Interval This optional parameter sets the period of time for which the truck will lift once traction is commanded while Quick Lift mode.

This parameter has two functions: •

Sets the minimum time for the BDI to count down from 100% to 0%. If upon verification battery voltage is below corresponding BDI percent, BDI percent will decrement by one percentage point.

Lift Run Time This parameter sets the maximum allowable time to have the motor pump running upon lift command.

BDI Warning (Lift Lock) Enable This parameter enables the truck to lock the lift function when BDI reaches a given percent Warning BDI (Lift Lock Out Percent) This parameter will set the battery discharge percentage at which the truck will lock the lift function Battery-BDI Reset Volts The reset voltage level is checked only once, when KSI is first turned on. Note that the BDI Reset Percent parameter also influences the algorithm that determines whether BDI Percentage is reset to 100%. Reset Volts Per Cell should always be set higher than Full Volts Per Cell.

A. OPERATIONAL REGION A B. OPERATIONAL REGION B C. OPERATIONAL REGION C Figure 9030-03-3. Operational Regions

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9030-03-11

General Maintenance and Diagnostic Data •

Sets the frequency at which the BDI will check the battery voltage. If upon verification battery voltage is below corresponding BDI percent, BDI percent will decrement by one percentage point.

ELECTRICAL SYSTEM Total Maintenance Enable This parameter will activate BDI maintenance reminder for truck to be serviced after certain amount of total hours have been accumulated in the hour meters.

Battery-BDI Reset Percent Traction Maintenance Enable When a battery has a high BDI percentage, its float voltage at KSI On can sometimes cause false resets.

The BDI Reset Percent parameter addresses this problem by allowing the user to define a BDI Percentage value above which the BDI Percentage variable will not reset.

This parameter will activate BDI maintenance reminder for truck to be serviced after certain amount of Traction hours have been accumulated in the hour meters.

Pump Maintenance Enable

Undervoltage Cutback Range Severe Undervoltage = Undervoltage point – Undervoltage Cutback Range or Brownout voltage (15V) whichever is higher. This parameter sets the voltage range between the Undervoltage and Severe Undervoltage points. A Severe Undervoltage fault will be set if the capacitor voltage falls below either the Severe Undervoltage point (drive current limit set to 0) or the Brownout voltage (bridge disabled, motor current set to 0).

This parameter will activate BDI maintenance reminder for truck to be serviced after certain amount of Pump hours have been accumulated in the hour meters.

Maintenance Interval This parameter will sets the time interval at which the truck shall receive regular maintenance.

Reset Total Maintenance

User Undervoltage Undervoltage = Either Min Voltage controller voltage (16.8V) or User Undervoltage × Nominal Voltage, whichever is higher. The User Undervoltage parameter can be used to adjust the undervoltage threshold, which is the voltage at which the controller will cut back drive current to prevent damage to the electrical system. The undervoltage threshold can never be lowered below the controller’s power base minimum voltage rating.

This parameter will set back to zero the maintenance interval counter.

Reset Traction Maintenance This parameter will set back to zero the maintenance interval counter.

Reset Pump Maintenance This parameter will set back to zero the maintenance interval counter.

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9030-03-12

ELECTRICAL SYSTEM

General Maintenance and Diagnostic Data

Status Codes and Descriptions STATUS CODES Status codes give an indication to the operator that a possible malfunction or incorrect truck use has occurred. Status codes are a code number of a symptom or malfunction. The wrench symbol will flash and the status code number will be shown on the LCD screen if an incorrect truck use or malfunction occurs during operation. Have an authorized service person check and repair the lift truck if a status code number appears. The symptoms for each status code are shown

in this manual. This manual also provides in-depth troubleshooting procedures for each fault broken down into the following system or node: NODE 30: TRACTION CONTROLLER NODE 60: TILLER CARD Status Codes are displayed as four lines. Line one consist of the Node and Code number. The second line consists of the Node name while lines three and four contain code descriptions.

Table 9030-03-1. Status Code Example DISPLAY

LINE DESCRIPTION

First Display String

Diagnostic Trouble Code

Subsequent Display String

Code Description/Affected Circuit

STATUS CODE DESCRIPTIONS Table 9030-03-2. Node 30 Status Codes NODE

STATUS

DESCRIPTION

XX

099

Internal Fault*

30

001

The Traction Controller has detected a fault in the Lift Coil circuit.

30

003

The Traction Controller has detected a fault in the Lower Coil circuit.

30

033

The Traction Controller has detected a fault in the Main Contactor Coil circuit.

30

035

The Traction Controller had detected a fault in the Brake Coil circuit.

30

037

The Traction Controller has detected a fault in the Audible Alarm circuit.

30

039

The Traction Controller has detected a fault in the Optional Audible Alarm circuit.

30

052

The Traction Controller has detected a fault in the Beverage Handle Option, Thumb Lift/ Lower Switch circuit.

30

060

The Traction Controller has detected high current in the traction motor or traction motor circuit.

30

061

The Traction Controller has detected a open/short in the Traction Motor or circuit.

30

062

The Traction Controller has detected a motor encoder fault.

30

067

The Traction Controller has detected that the Main Contactor is stuck closed or has welded tips.

30

068

The Traction Controller has detected that the Main Contactor is not closed or stuck open.

30

069

The Traction Controller has detected a fault in Capacitor charge.

30

080

The Traction Controller has detected the motor operating at high temperatures/Cutback Mode.

30

082

The Traction Controller is operating at high temperatures/Cutback Mode.

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9030-03-13

General Maintenance and Diagnostic Data

ELECTRICAL SYSTEM

Table 9030-03-2. Node 30 Status Codes (Continued) NODE

STATUS

DESCRIPTION

30

083

The Traction Controller has detected temperatures above controllers operating range.

30

086

The Traction Controller has detected Low DC Bus Voltage or a fault in the DC Bus circuit.

30

087

The Traction Controller has detected High DC Bus Voltage or a fault in the DC Bus circuit.

30

090

The Traction Controller has detected a fault in the 5 volt/12 volt output supply.

30

106

The Tiller Card is not communicating on the CANbus.

30

201

The Traction Controller has detected a Throttle release fault.

30

227

The Traction Controller has detected that the traction motor has stalled.

30

231

The Traction Controller has set the maintenance reminder.

30

232

The Traction Controller has detected software update request.

30

247

The Traction Controller has detected parameter update request.

30

248

The Traction Controller has detected temperatures below controller operating range.

*The Traction Controller and Tiller Control Card can detect an internal fault and is capable of reporting a 099 Status Code. Refer to the XX099 Status Code troubleshooting procedures for all Internal Fault Codes regardless of what Node has reported the fault.

Table 9030-03-3. Node 60 Status Codes NODE

STATUS

DESCRIPTION

60

050

The Tiller Control Card has detected a Belly Switch Mismatch fault.

60

210

The Tiller Control Card has detected a Belly Switch release fault.

60

211

The Tiller Control Card has detected a Tiller Arm release fault.

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9030-03-14

ELECTRICAL SYSTEM

Diagnostic Trouble Codes

Group 20

Diagnostic Trouble Codes DTC XX099 Internal Fault POSSIBLE CAUSE A. INTERNAL FAULT COMPONENT OPERATIONAL CHECK NOTE: Always check battery condition and state of charge before performing electrical troubleshooting. A faulty or low charged battery will cause electrical features to not operate as designed and give incorrect readings while performing electrical tests.

PROCEDURE OR ACTION: 1. Conduct a visual inspection of all connectors/wiring associated with the fault code.

Are any faults detected/observed?

YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical System SRM. NO: Proceed to Step 2.

2. Re-key the vehicle.

Is the code still present?

YES: Proceed to Cause A. NO: Problem may be intermittent.

CAUSE A - INTERNAL FAULT PROCEDURE OR ACTION: 1. Replace faulty controller or tiller card. Make sure to indicate the Diagnostic Trouble Code on the warranty claim to include an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES END FAULT

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9030-20-1

Diagnostic Trouble Codes

ELECTRICAL SYSTEM

DTC 30001 LiftCoil POSSIBLE CAUSE A. LIFT COIL WIRING FAULT B. LIFT COIL FAULT C. FAULTY TRACTION CONTROLLER NOTE Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK NOTE: Always check battery condition and state of charge before performing electrical troubleshooting. A faulty or low charged battery will cause electrical features to not operate as designed and give incorrect readings while performing electrical tests.

PROCEDURE OR ACTION: 1. Conduct a visual inspection of all connectors/wiring associated with the fault code.

Are any faults detected/observed?

YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical System SRM ..

NO: Proceed to Step 2.

2. Re-key the vehicle.

Is the code still present?

YES: Proceed to Cause A. NO: Problem may be intermittent.

CAUSE A - LIFT COIL WIRING FAULT PROCEDURE OR ACTION: NOTE: Disconnect pump coil terminals TS11 and TS12 located on left side of traction controller. Turn key to ON position.

1. Measure voltage between pump coil terminal TS11 and B(-).

Is voltage 24 ± 2.5 Vdc? YES: Disconnect battery and proceed to Step 2.

NO: Inspect circuit 239 for open or short.

2. Disconnect connector CPS01 and measure resistance between socket 4 and the pump coil terminal TS11.

Is resistance <1 ohm?

YES: Connect CPS01, connect battery, and proceed to Step 3.

NO: Inspect circuit 028 for open, short, or source of excessive resistance.

3. Measure voltage between pump coil terminal TS12 and B(+) while operating tiller card lift switch.

Is voltage 24 ± 2.5 Vdc? YES: Disconnect battery and proceed to Cause B. NO: Proceed to Cause C.

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9030-20-2

ELECTRICAL SYSTEM

Diagnostic Trouble Codes

DTC 30001 (Cont) LiftCoil CAUSE B - LIFT COIL FAULT PROCEDURE OR ACTION: 1. At the pump coil contacts, measure resistance between the parallel terminal tabs.

Is resistance 55 ± 5.25 ohms?

YES: Proceed to Cause C. NO: Replace faulty lift coil.

CAUSE C - FAULTY TRACTION CONTROLLER PROCEDURE OR ACTION: 1. If no faults are found, replace controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES

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9030-20-3

Diagnostic Trouble Codes

ELECTRICAL SYSTEM

DTC 30001 (Cont) LiftCoil DIAGRAMS

Lift Coil and Pump Contactor END FAULT

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9030-20-4

ELECTRICAL SYSTEM

Diagnostic Trouble Codes

DTC 30003 LwrCoil POSSIBLE CAUSE A. LOWER COIL WIRING FAULT B. LOWER COIL FAULT C. FAULTY TRACTION CONTROLLER NOTE Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK NOTE: Always check battery condition and state of charge before performing electrical troubleshooting. A faulty or low charged battery will cause electrical features to not operate as designed and give incorrect readings while performing electrical tests.

PROCEDURE OR ACTION: 1. Conduct a visual inspection of all connectors/wiring associated with the fault code.

Are any faults detected/observed?

YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical System SRM ..

NO: Proceed to Step 2.

2. Re-key the vehicle.

Is the code still present?

YES: Proceed to Cause A. NO: Problem may be intermittent.

CAUSE A - LOWER COIL WIRING FAULT PROCEDURE OR ACTION: NOTE: Disconnect lower coil connector CRS05 located within hydraulic pump motor and turn key to ON position.

1. Measure voltage between lower coil connector CRS05, socket 1 and B(-).

Is voltage 24 ± 2.5 Vdc? YES: Disconnect battery and proceed to Step 2.

NO: Inspect circuit 239 for open or short.

2. Disconnect lower coil connector CPS01 and measure continuity between CRS05, socket 2 and CPS 01, socket 3.

Is resistance <1 ohm?

YES: Connect CPS01, connect battery, and proceed to Step 3.

NO: Inspect circuit 801 for open, short, or source of excessive resistance.

3. Measure voltage between CRS05, socket 2 and B(+) while operating tiller card lower switch.

Is voltage 24 ± 2.5 Vdc? YES: Disconnect battery and proceed to Cause B. NO: Proceed to Cause C.

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9030-20-5

Diagnostic Trouble Codes

ELECTRICAL SYSTEM

DTC 30003 (Cont) LwrCoil CAUSE B - LOWER COIL FAULT PROCEDURE OR ACTION: 1. Measure resistance between the parallel terminal tabs at the valve coil contacts.

Is resistance 19 ± 2.0 ohms?

YES: Proceed to Cause C. NO: Replace faulty lower coil.

CAUSE C - FAULTY TRACTION CONTROLLER PROCEDURE OR ACTION: 1. If no faults are found, replace controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES

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9030-20-6

ELECTRICAL SYSTEM

Diagnostic Trouble Codes

DTC 30003 (Cont) LwrCoil DIAGRAMS

Lower Coil and Pump Motor END FAULT

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9030-20-7

Diagnostic Trouble Codes

ELECTRICAL SYSTEM

DTC 30033 Main Cont POSSIBLE CAUSE A. MAIN CONTACTOR COIL WIRING FAULT B. MAIN CONTACTOR COIL FAULT C. FAULTY TRACTION CONTROLLER NOTE Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK NOTE: Always check battery condition and state of charge before performing electrical troubleshooting. A faulty or low charged battery will cause electrical features to not operate as designed and give incorrect readings while performing electrical tests.

PROCEDURE OR ACTION: 1. Conduct a visual inspection of all connectors/wiring associated with the fault code.

Are any faults detected/observed?

YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical System SRM .

NO: Proceed to Step 2.

2. Re-key the vehicle.

Is the code still present?

YES: Proceed to Cause A. NO: Problem may be intermittent.

CAUSE A - MAIN CONTACTOR COIL WIRING FAULT PROCEDURE OR ACTION: NOTE: Key in ON position.

1. Disconnect the main contactor coil's positive socket terminal TS007 and measure voltage between socket terminal TS007 and B(-).

Is voltage 24 ± 2.5 Vdc? YES: Proceed to Step 2.

NO: Inspect circuit W239-B for open or short.

NOTE: Key in OFF position.

2. Disconnect traction controller connector CPS001 and the contactor coil's negative socket terminal TS008.

Measure resistance between the main contactor coil negative socket terminal TS008 and the traction controller connector CPS001, socket 6.

Is resistance <1 ohm?

YES: Proceed to Cause B. NO: Inspect ground control circuit 075 for open or source of excessive resistance.

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9030-20-8

ELECTRICAL SYSTEM

Diagnostic Trouble Codes

DTC 30033 (Cont) Main Cont CAUSE B - MAIN CONTACTOR COIL FAULT PROCEDURE OR ACTION: NOTE: Key in OFF position.

1. Measure resistance between the main contactor's coil terminals.

Is resistance 30 ± 3.0 ohms?

YES: Proceed to Cause C. NO: Replace faulty main contactor coil.

CAUSE C - FAULTY TRACTION CONTROLLER PROCEDURE OR ACTION: 1. If no faults are found, replace controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES

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9030-20-9

Diagnostic Trouble Codes

ELECTRICAL SYSTEM

DTC 30033 (Cont) Main Cont DIAGRAMS

Battery Disconnect / Main Contactor and Contactor Coil END FAULT

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9030-20-10

ELECTRICAL SYSTEM

Diagnostic Trouble Codes

DTC 30035 Brake POSSIBLE CAUSE A. WIRING FAULT B. BRAKE COIL FAULT C. FAULTY TRACTION CONTROLLER NOTE Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK NOTE: Always check battery condition and state of charge before performing electrical troubleshooting. A faulty or low charged battery will cause electrical features to not operate as designed and give incorrect readings while performing electrical tests.

PROCEDURE OR ACTION: 1. Conduct a visual inspection of all connectors/wiring associated with the fault code.

Are any faults detected/observed?

YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical System SRM .

NO: Proceed to Step 2.

2. Re-key the vehicle.

Is the code still present?

YES: Proceed to Cause A. NO: Fault may be intermittent.

CAUSE A - WIRING FAULT PROCEDURE OR ACTION: NOTE: Perform Step 1 with key in ON position.

1. Disconnect CPS01 and measure voltage between CPS01, socket 1 and B(-). Note voltage reading, reconnect CPS01, cycle key switch. Disconnect brake coil connector CRP04-A and measure voltage between CRP04-A, socket 1 and B(-).

Is voltage same as key switch input?

YES: Disconnect battery and proceed to Cause B. NO: Inspect circuit 239 for open or short.

CAUSE B - BRAKE COIL FAULT PROCEDURE OR ACTION: 1. Measure resistance between CPS01, socket 5 and CRP04-A, socket 1.

Is resistance 23 ± 2.3 ohms?

YES: Proceed to Cause C. NO: Replace faulty brake coil.

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9030-20-11

Diagnostic Trouble Codes

ELECTRICAL SYSTEM

DTC 30035 (Cont) Brake CAUSE C - FAULTY TRACTION CONTROLLER PROCEDURE OR ACTION: 1. If no faults are found, replace controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES

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9030-20-12

ELECTRICAL SYSTEM

Diagnostic Trouble Codes

DTC 30035 (Cont) Brake DTC 30035 BRAKE DIAGRAMS

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9030-20-13

Diagnostic Trouble Codes

ELECTRICAL SYSTEM

DTC 30035 (Cont) Brake

Brake Coil END FAULT

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9030-20-14

ELECTRICAL SYSTEM

Diagnostic Trouble Codes

DTC 30037 AlrmCoil POSSIBLE CAUSE A. ALARM WIRING FAULT B. ALARM FAULT C. FAULTY TRACTION CONTROLLER NOTE Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK NOTE: Always check battery condition and state of charge before performing electrical troubleshooting. A faulty or low charged battery will cause electrical features to not operate as designed and give incorrect readings while performing electrical tests.

PROCEDURE OR ACTION: 1. Conduct a visual inspection of all connectors/wiring associated with the fault code.

Are any faults detected/observed?

YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical System SRM .

NO: Proceed to Step 2.

2. Re-key the vehicle.

Is the code still present?

YES: Proceed to Cause A. NO: Problem may be intermittent.

CAUSE A - ALARM WIRING FAULT PROCEDURE OR ACTION: NOTE: Perform Step 1 with key in ON position.

1. Disconnect alarm connector TS09 and measure voltage between socket 1 and B(-).

Is voltage 24 ± 2.5 Vdc? YES: Disconnect battery and proceed to Step 2.

NO: Inspect circuit 239 for open or short.

2. Disconnect the traction connector CPS01. Measure resistance between the traction connector CPS01, socket 20 and the alarm connector TS09.

Is resistance <1 ohm?

YES: Connect traction controller connector CPS01 and proceed to Cause B. NO: Inspect ground control circuit 045 for open or short.

CAUSE B - ALARM FAULT PROCEDURE OR ACTION: NOTE: Key in ON position.

NOTE: Operate alarm.

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9030-20-15

Diagnostic Trouble Codes

ELECTRICAL SYSTEM

DTC 30037 (Cont) AlrmCoil 1. Measure continuity between the alarm connector TS09 and B(-).

Is continuity present?

YES: Replace faulty alarm.

NO: Proceed to Cause C. CAUSE C - FAULTY TRACTION CONTROLLER PROCEDURE OR ACTION: 1. If no faults are found, replace controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES

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9030-20-16

ELECTRICAL SYSTEM

Diagnostic Trouble Codes

DTC 30037 (Cont) AlrmCoil DIAGRAMS

Horn / Alarm END FAULT

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9030-20-17

Diagnostic Trouble Codes

ELECTRICAL SYSTEM

DTC 30039 Audible Alarm (Opt) POSSIBLE CAUSE A. ALARM WIRING FAULT B. ALARM FAULT C. FAULTY TRACTION CONTROLLER NOTE Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK NOTE: Always check battery condition and state of charge before performing electrical troubleshooting. A faulty or low charged battery will cause electrical features to not operate as designed and give incorrect readings while performing electrical tests.

PROCEDURE OR ACTION: 1. Conduct a visual inspection of all connectors/wiring associated with the fault code.

Are any faults detected/observed?

YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical System SRM .

NO: Proceed to Step 2.

2. Re-key the vehicle.

Is the code still present?

YES: Proceed to Cause A. NO: Problem may be intermittent.

CAUSE A - ALARM WIRING FAULT PROCEDURE OR ACTION: NOTE: Perform Step 1 with key in ON position.

1. Disconnect optional alarm connector CPS13 and measure voltage between socket 1 and B(-).

Is voltage 24 ± 2.5 Vdc? YES: Disconnect battery and proceed to Step 2.

NO: Inspect circuit 010 for open or short.

2. Disconnect the traction connector CPS01. Measure resistance between the traction connector CPS01, socket 2 and the alarm connector CPS13, socket 2.

Is resistance <1 ohm?

YES: Connect traction controller connector CPS01 and proceed to Cause B. NO: Inspect ground control circuit 728 for open, short, or source of excessive resistance.

CAUSE B - ALARM FAULT PROCEDURE OR ACTION: NOTE: Key in ON position.

NOTE: Operate optional alarm.

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9030-20-18

ELECTRICAL SYSTEM

Diagnostic Trouble Codes

DTC 30039 (Cont) Audible Alarm (Opt) 1. Measure continuity between the optional alarm connector CPS13, socket 2 and B(-).

Is continuity present?

YES: Replace faulty optional alarm.

NO: Proceed to Cause C. CAUSE C - FAULTY TRACTION CONTROLLER PROCEDURE OR ACTION: 1. If no faults are found, replace controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES

END FAULT

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9030-20-19

Diagnostic Trouble Codes

ELECTRICAL SYSTEM

CODES DTC 30060 - Mtr Curr DTC 30061 - Mtr Open POSSIBLE CAUSE A. TRACTION MOTOR CABLE FAULT B. TRACTION MOTOR FAULT C. FAULTY TRACTION CONTROLLER NOTE Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK NOTE: Always check battery condition and state of charge before performing electrical troubleshooting. A faulty or low charged battery will cause electrical features to not operate as designed and give incorrect readings while performing electrical tests.

PROCEDURE OR ACTION: 1. Conduct a visual inspection of all connectors/wiring associated with the fault code.

Are any faults detected/observed?

YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical System SRM .

NO: Proceed to Step 2.

2. Re-key the vehicle.

Is the code still present?

YES: Proceed to Cause A. NO: Problem may be intermittent.

CAUSE A - TRACTION MOTOR CABLE FAULT PROCEDURE OR ACTION: 1. Inspect controller phase cable terminals for proper torque and connections.

Are phase cables properly secured?

YES: Proceed to Step 2.

NO: Repair and properly torque cables.

2. Disconnect the traction motor cables from the traction controller and traction motor. Measure continuity of individual cables to isolate fault.

Is continuity present?

YES: Disconnect battery and proceed to Cause B. NO: Repair or replace faulty phase cable.

CAUSE B - TRACTION MOTOR FAULT PROCEDURE OR ACTION: 1. Measure continuity between the traction motor terminals U and V. Is continuity present?

YES: Proceed to Step 2.

NO: Repair or replace faulty traction motor.

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9030-20-20

ELECTRICAL SYSTEM

Diagnostic Trouble Codes

(Cont) 2. Measure continuity between the traction motor terminals U and W. Is continuity present?

YES: Proceed to Step 3.

NO: Repair or replace faulty traction motor.

3. Measure continuity between the traction motor terminals W and V. Is continuity present?

YES: Proceed to Cause C. NO: Repair or replace faulty traction motor.

CAUSE C - FAULTY TRACTION CONTROLLER PROCEDURE OR ACTION: 1. If no faults are found, replace controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES DIAGRAMS

Traction Motor END FAULT

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9030-20-21

Diagnostic Trouble Codes

ELECTRICAL SYSTEM

DTC 30062 Encoder POSSIBLE CAUSE A. ENCODER WIRING FAULT B. ENCODER FAULT C. FAULTY TRACTION CONTROLLER NOTE Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK NOTE: Always check battery condition and state of charge before performing electrical troubleshooting. A faulty or low charged battery will cause electrical features to not operate as designed and give incorrect readings while performing electrical tests.

PROCEDURE OR ACTION: 1. Conduct a visual inspection of all connectors/wiring associated with the fault code.

Are any faults detected/observed?

YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical System SRM .

NO: Proceed to Step 2.

2. Re-key the vehicle.

Is the code still present?

YES: Proceed to Cause A. NO: Problem may be intermittent.

CAUSE A - ENCODER WIRING FAULT PROCEDURE OR ACTION: 1. Disconnect the traction motor encoder connector CPS03 and measure voltage between socket 1 and B(-).

Is voltage 5 ± 0.5 Vdc? YES: Proceed to Step 2.

NO: Inspect circuit 250 for open or short.

2. Measure voltage between the encoder connector CPS03, socket 1 and socket 4.

Is voltage 5 ± 0.5 Vdc? YES: Disconnect battery and proceed to Step 3.

NO: Inspect ground circuit 102 for open or short.

3. Disconnect the Combination controller connector CPS01. Measure resistance between socket 32 of the Combination controller connector and socket 3 of the encoder connector CPS03.

Is resistance <1 ohm?

YES: Proceed to Step 4.

NO: Inspect signal circuit 578 for open or source of excessive resistance.

4. Measure resistance between socket 31 of the Combination controller connector CPS01 and socket 2 of the encoder connector CPS03.

Is resistance <1 ohm?

YES: Reconnect the encoder connector CPS003, battery, and proceed to Cause B. NO: Inspect signal circuit 577 for open or source of excessive resistance.

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9030-20-22

ELECTRICAL SYSTEM

Diagnostic Trouble Codes

DTC 30062 (Cont) Encoder CAUSE B - ENCODER FAULT PROCEDURE OR ACTION: NOTE: Connect battery.

NOTE: Operate traction motor while performing this test. Voltage output will alternate between 5 Vdc and 0 Vdc as motor rotates.

1. Disconnect the Combination controller connector CPS01 and measure voltage between socket 13, 14, and B(-).

Does voltage signal relate to traction motor movement?

YES: Proceed to Cause C. NO: Replace faulty encoder.

CAUSE C - FAULTY TRACTION CONTROLLER PROCEDURE OR ACTION: 1. If no faults are found, replace controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES

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9030-20-23

Diagnostic Trouble Codes

ELECTRICAL SYSTEM

DTC 30062 (Cont) Encoder DTC 30062 ENCODER DIAGRAMS

Traction Motor END FAULT

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9030-20-24

ELECTRICAL SYSTEM

Diagnostic Trouble Codes

DTC 30067 MainCont (Stuck Closed) POSSIBLE CAUSE A. MAIN CONTACTOR COIL WIRING FAULT B. MAIN CONTACTOR STUCK CLOSED C. FAULTY TRACTION CONTROLLER NOTE Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK NOTE: Always check battery condition and state of charge before performing electrical troubleshooting. A faulty or low charged battery will cause electrical features to not operate as designed and give incorrect readings while performing electrical tests.

PROCEDURE OR ACTION: 1. Conduct a visual inspection of all connectors/wiring associated with the fault code.

Are any faults detected/observed?

YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical System SRM. NO: Proceed to Step 2.

2. Re-key the vehicle.

Is the code still present?

YES: Proceed to Cause A. NO: Problem may be intermittent.

CAUSE A - MAIN CONTACTOR COIL WIRING FAULT PROCEDURE OR ACTION: NOTE: Key in ON position.

1. Disconnect the main contactor coil's positive socket terminal TS07 and measure voltage between the terminal and B(-).

Is voltage 24 ± 2.5 Vdc? YES: Disconnect battery and proceed to Step 2.

NO: Inspect circuit 239 for open or short.

2. Disconnect the traction controller connector CPS01 and the contactor coil negative terminal TS08. Measure continuity between TS08 and socket 6 of the traction controller CPS01.

Is continuity present?

YES: Reconnect battery and all connectors. Proceed to Cause B. NO: Inspect ground control circuit 075 for open or short.

CAUSE B - MAIN CONTACTOR STUCK CLOSED PROCEDURE OR ACTION: NOTE: Key in OFF position.

1. Measure voltage between controller B(+) and controller B(-).

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9030-20-25

Diagnostic Trouble Codes

ELECTRICAL SYSTEM

DTC 30067 (Cont) MainCont (Stuck Closed) Is voltage 24 ± 2.5 Vdc? YES: Replace faulty main contactor.

NO: Proceed to Cause C. CAUSE C - FAULTY TRACTION CONTROLLER PROCEDURE OR ACTION: 1. If no faults are found, replace controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES

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9030-20-26

ELECTRICAL SYSTEM

Diagnostic Trouble Codes

DTC 30067 (Cont) MainCont (Stuck Closed) DIAGRAMS

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9030-20-27

Diagnostic Trouble Codes

ELECTRICAL SYSTEM

DTC 30067 (Cont) MainCont (Stuck Closed)

Main Contactor END FAULT

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9030-20-28

ELECTRICAL SYSTEM

Diagnostic Trouble Codes

DTC 30068 MainCont (Stuck Open) POSSIBLE CAUSE A. B. C. D.

MAIN CONTACTOR COIL WIRING FAULT FAULTY B(+) CONNECTION MAIN CONTACTOR STUCK OPEN FAULTY TRACTION CONTROLLER NOTE Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK NOTE: Always check battery condition and state of charge before performing electrical troubleshooting. A faulty or low charged battery will cause electrical features to not operate as designed and give incorrect readings while performing electrical tests.

PROCEDURE OR ACTION: 1. Conduct a visual inspection of all connectors/wiring associated with the fault code.

Are any faults detected/observed?

YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical System SRM. NO: Proceed to Step 2.

2. Re-key the vehicle.

Is the code still present?

YES: Proceed to Cause A. NO: Problem may be intermittent.

CAUSE A - MAIN CONTACTOR COIL WIRING FAULT PROCEDURE OR ACTION: NOTE: Key in ON position.

1. Disconnect the main contactor coil's positive socket terminal TS07 and measure voltage between the terminal and B(-).

Is voltage 24 ± 2.5 Vdc? YES: Disconnect battery and proceed to Step 2.

NO: Inspect circuit 239 for open or short.

2. Disconnect the traction controller connector CPS01 and the contactor coil negative terminal TS08. Measure continuity between TS08 and socket 6 of the traction controller CPS01.

Is continuity present?

YES: Reconnect battery and all connectors. Proceed to Cause B. NO: Inspect ground control circuit 075 for open or short.

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9030-20-29

Diagnostic Trouble Codes

ELECTRICAL SYSTEM

DTC 30068 (Cont) MainCont (Stuck Open) CAUSE B - FAULTY B(+) CONNECTION PROCEDURE OR ACTION: 1. Review basic electrical troubleshooting information and perform steps in the Voltage Checks. Rekey the truck and check for codes.

Is code still present?

YES: Proceed to Cause C. NO: Ensure all terminal lugs are appropriately torqued.

CAUSE C - MAIN CONTACTOR STUCK OPEN PROCEDURE OR ACTION: 1. Move tiller arm to UP position and measure voltage between controller B(+) and controller B(-) terminal. Operate turtle switch while measuring voltage.

Is voltage present between B(+) and B(-) terminals?

YES: Proceed to Cause D. NO: Replace faulty main contactor.

CAUSE D - FAULTY TRACTION CONTROLLER PROCEDURE OR ACTION: 1. If no faults are found, replace controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES

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9030-20-30

ELECTRICAL SYSTEM

Diagnostic Trouble Codes

DTC 30068 (Cont) MainCont (Stuck Open) DIAGRAMS

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9030-20-31

Diagnostic Trouble Codes

ELECTRICAL SYSTEM

DTC 30068 (Cont) MainCont (Stuck Open)

Main Contactor END FAULT

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9030-20-32

ELECTRICAL SYSTEM

Diagnostic Trouble Codes

DTC 30069 Precharge POSSIBLE CAUSE A. CONTROLLER WIRING FAULT B. FAULTY TRACTION CONTROLLER NOTE Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK NOTE: Always check battery condition and state of charge before performing electrical troubleshooting. A faulty or low charged battery will cause electrical features to not operate as designed and give incorrect readings while performing electrical tests.

PROCEDURE OR ACTION: 1. Conduct a visual inspection of all connectors/wiring associated with the fault code.

Are any faults detected/observed?

YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical System SRM .

NO: Proceed to Step 2.

2. Re-key the vehicle.

Is the code still present?

YES: Disconnect battery and discharge the capacitor. Connect battery and re-key the vehicle prior to performing Step 3.

NO: Problem may be intermittent.

NOTE: The capacitor bank will charge only when the main contactor is closed. If the truck is static, tiller arm up, no inputs commanded; the capacitor voltage is going to be 0 Vdc and KSI (Key Switch Input) voltage shall read battery voltage.

3. Connect to PC Service Tool, enable main contactor and view diagnostics for capacitor voltage and battery voltage.

Is CAP voltage same as battery voltage?

YES: Verify battery state of charge and recheck condition. If actual voltage does not agree with PC service tool diagnostics, proceed to Cause B. NO: Proceed to Cause A. CAUSE A - CONTROLLER WIRING FAULT PROCEDURE OR ACTION: 1. Measure voltage between the traction controller B(+) terminal and B(-).

Is precharge voltage same as battery voltage?

YES: Proceed to Cause B. NO: Check for external loads or shorts on the B(+) circuit and phase cables. Refer to the Basic Electrical Troubleshootingsection and perform Voltage Checks.

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9030-20-33

Diagnostic Trouble Codes

ELECTRICAL SYSTEM

DTC 30069 (Cont) Precharge CAUSE B - FAULTY TRACTION CONTROLLER PROCEDURE OR ACTION: 1. If no faults are found, replace controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES

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9030-20-34

ELECTRICAL SYSTEM

Diagnostic Trouble Codes

DTC 30069 (Cont) Precharge

END FAULT

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9030-20-35

Diagnostic Trouble Codes

ELECTRICAL SYSTEM

DTC 30080 OverHeat POSSIBLE CAUSE A. WIRING FAULT B. FAULTY TRACTION CONTROLLER NOTE Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK NOTE: Always check battery condition and state of charge before performing electrical troubleshooting. A faulty or low charged battery will cause electrical features to not operate as designed and give incorrect readings while performing electrical tests.

PROCEDURE OR ACTION: 1. Conduct a visual inspection of all connectors/wiring associated with the fault code.

Are any faults detected/observed?

YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical System SRM .

NO: Proceed to Step 2.

2. Re-key the vehicle.

Is the code still present?

YES: Proceed to Step 3.

NO: Fault may be intermittent.

3. Reduce truck usage and allow controller to cool for approximately 15 minutes. System will recover once temperature is below 115°C (239°F) for the traction motor and 85°C (185°F) for the traction controller.

Is the code still present?

YES: Proceed to Cause A. NO: Fault may be intermittent. Review truck usage, weight load, and rated capacities.

CAUSE A - WIRING FAULT PROCEDURE OR ACTION: 1. Perform Voltage Checks as indicated in the Basic Electrical Troubleshooting section.

Did code clear?

YES: Clear error log and verify correct operation.

NO: Disconnect battery and proceed to Step 2.

2. Disconnect CPS01 and CPS02. Measure resistance between CPS01, socket 8 and CPS02, socket 1.

Is resistance ≤ 1 ohm?

YES: Connect CPS01 and proceed to Step 3.

NO: Inspect circuit 367 for open, short, or source of excessive resistance.

3. Measure resistance between CPS02, socket 2 and B(-). is resistance ≤ 1 ohm?

YES: Proceed to Cause B. NO: Inspect circuit 101 for open or shorts.

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9030-20-36

ELECTRICAL SYSTEM

Diagnostic Trouble Codes

DTC 30080 (Cont) OverHeat CAUSE B - FAULTY TRACTION CONTROLLER PROCEDURE OR ACTION: 1. If no faults are found, replace controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES DTC 30080 OVERHEAT DIAGRAMS

Traction Motor END FAULT

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9030-20-37

Diagnostic Trouble Codes

ELECTRICAL SYSTEM

DTC 30086 LowBatt POSSIBLE CAUSE A. LOW BATTERY CONDITION B. CONTROLLER WIRING FAULT C. FAULTY CONTROLLER NOTE Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK NOTE: Always check battery condition and state of charge before performing electrical troubleshooting. A faulty or low charged battery will cause electrical features to not operate as designed and give incorrect readings while performing electrical tests.

PROCEDURE OR ACTION: 1. Conduct a visual inspection of all connectors/wiring associated with the fault code.

Are any faults detected/observed?

YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical System SRM. NO: Proceed to Step 2.

2. Re-key the vehicle.

Is the code still present?

YES: Disconnect battery and discharge the capacitor. Connect battery and re-key the vehicle prior to performing Cause A. NO: Problem may be intermittent.

CAUSE A - LOW BATTERY CONDITION PROCEDURE OR ACTION: 1. Measure voltage between B(-) at the controller and FU1 (above controller).

Is voltage 25 ± 0.5 Vdc? YES: Proceed to Cause B. NO: Charge battery.

CAUSE B - CONTROLLER WIRING FAULT PROCEDURE OR ACTION: NOTE: Key in OFF position.

1. Measure voltage between the traction controller B(+) terminal and B(-).

Is precharge voltage same as battery voltage?

YES: Proceed to Cause C. NO: Inspect B(+) cable for damage or loose connections.

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9030-20-38

ELECTRICAL SYSTEM

Diagnostic Trouble Codes

DTC 30086 (Cont) LowBatt CAUSE C - FAULTY CONTROLLER PROCEDURE OR ACTION: 1. If no faults are found, replace controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES

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9030-20-39

Diagnostic Trouble Codes

ELECTRICAL SYSTEM

DTC 30086 (Cont) LowBatt

END FAULT

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9030-20-40

ELECTRICAL SYSTEM

Diagnostic Trouble Codes

DTC 30087 OverVolt POSSIBLE CAUSE A. HIGH VOLTAGE AT CONTROLLER TERMINALS B. CONTROLLER WIRING FAULT C. FAULTY CONTROLLER NOTE Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK NOTE: Always check battery condition and state of charge before performing electrical troubleshooting. A faulty or low charged battery will cause electrical features to not operate as designed and give incorrect readings while performing electrical tests.

PROCEDURE OR ACTION: 1. Conduct a visual inspection of all connectors/wiring associated with the fault code.

Are any faults detected/observed?

YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical System SRM. NO: Proceed to Step 2.

2. Re-key the vehicle.

Is the code still present?

YES: Disconnect battery and discharge the capacitor. Connect battery and re-key the vehicle prior to performing Cause A. NO: Problem may be intermittent.

CAUSE A - HIGH VOLTAGE AT CONTROLLER TERMINALS PROCEDURE OR ACTION: 1. Measure voltage between B(-) at the controller and FU1 (above controller).

Is voltage above 26 Vdc? YES: Ensure battery is rated at 24V and is properly connected to the truck.

NO: Proceed to Cause B. CAUSE B - CONTROLLER WIRING FAULT PROCEDURE OR ACTION: NOTE: Key in OFF position.

1. Measure voltage between the traction controller B(+) terminal and B(-).

Is precharge voltage same as battery voltage?

YES: Proceed to Cause C. NO: Inspect B(+) cable for damage or loose connections.

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9030-20-41

Diagnostic Trouble Codes

ELECTRICAL SYSTEM

DTC 30087 (Cont) OverVolt CAUSE C - FAULTY CONTROLLER PROCEDURE OR ACTION: 1. If no faults are found, replace controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES

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9030-20-42

ELECTRICAL SYSTEM

Diagnostic Trouble Codes

DTC 30087 (Cont) OverVolt

END FAULT

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9030-20-43

Diagnostic Trouble Codes

ELECTRICAL SYSTEM

DTC 30090 12 Vdc / 5 Vdc Supply Output POSSIBLE CAUSE A. B. C. D.

WIRING FAULT BATTERY DISPLAY FAULT ENCODER FAULT TRACTION CONTROLLER FAULT NOTE Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK NOTE: Always check battery condition and state of charge before performing electrical troubleshooting. A faulty or low charged battery will cause electrical features to not operate as designed and give incorrect readings while performing electrical tests.

PROCEDURE OR ACTION: 1. Conduct a visual inspection of all connectors/wiring associated with the fault code.

Are any faults detected/observed?

YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical System SRM. NO: Proceed to Step 2.

2. Re-key the vehicle.

Is the code still present?

YES: Proceed to Step 3.

NO: Problem may be intermittent.

3. Using the PC Service Tool, locate input diagnostics.

Is thumb switch activation detected?

YES: Fault may be intermittent.

NO: Proceed to Cause A. CAUSE A - WIRING FAULT PROCEDURE OR ACTION: NOTE: Key in ON position 1. Disconnect battery display connector CRS07.

Did the code clear upon rekey?

YES: Proceed to Cause B. NO: Proceed to Step 2.

2. Disconnect encoder connector CPS03.

Did the code clear upon rekey?

YES: Proceed to Cause C. NO: Proceed to Step 3.

3. With encoder connector and battery display connector removed, measure voltage between CRS07, socket 5 and B(-).

Is voltage 12 ± 1.5 Vdc? YES: Proceed to Step 4.

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9030-20-44

ELECTRICAL SYSTEM

Diagnostic Trouble Codes

DTC 30090 (Cont) 12 Vdc / 5 Vdc Supply Output NO: Disconnect battery and proceed to Step 5.

4. Measure voltage between CRS03, socket 4 and B(-).

Is voltage 12 ± 1.5 Vdc? YES: Proceed to Cause D. NO: Disconnect battery and proceed to Step 6.

5. Disconnect controller connector CPS01, encoder CPS03, and battery display CRS07. Measure resistance between CRS07, socket 5 and CPS01, socket 25.

Is resistance ≤ 1 ohm?

YES: Proceed to Cause D. NO: Inspect circuit 032 for open, short, or source of excessive resistance.

6. Disconnect controller connector CPS01, encoder CPS03, and battery display CRS07. Measure resistance between CPS03, socket 1 and CPS01, socket 26. is resistance ≤ 1 ohm?

YES: Proceed to Cause D. NO: Inspect circuit 250 for open, short, or source of excessive resistance.

CAUSE B - BATTERY DISPLAY FAULT PROCEDURE OR ACTION: 1. If faults are found when reconnecting, replace BDI. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate problem description leading to controller replacement.

CAUSE C - ENCODER FAULT PROCEDURE OR ACTION: 1. if faults are found when reconnecting, replace encoder. make sure to indicate the DTC code(s) on the warranty claim to include an accurate problem description leading to controller replacement.

CAUSE D - TRACTION CONTROLLER FAULT PROCEDURE OR ACTION: 1. If no faults are found, replace controller. Make sure to indicate the DTC code(s) on the warranty claim to include and accurate problem description leading to controller replacement.

END POSSIBLE CAUSES

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9030-20-45

Diagnostic Trouble Codes

ELECTRICAL SYSTEM

DTC 30090 (Cont) 12 Vdc / 5 Vdc Supply Output

END FAULT

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9030-20-46

ELECTRICAL SYSTEM

Diagnostic Trouble Codes

DTC 30106 CANcomm POSSIBLE CAUSE A. CANBUS COMMUNICATION FAULT B. TILLER CARD WIRING FAULT C. FAULTY HANDLE NOTE Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK NOTE: Always check battery condition and state of charge before performing electrical troubleshooting. A faulty or low charged battery will cause electrical features to not operate as designed and give incorrect readings while performing electrical tests.

PROCEDURE OR ACTION: 1. Conduct a visual inspection of all connectors/wiring associated with the fault code.

Are any faults detected/observed?

YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical System SRM .

NO: Proceed to Step 2.

2. Re-key the vehicle.

Is the code still present?

YES: Proceed to Step 3.

NO: Problem may be intermittent.

3. Perform multiplexing checks, see the Multiplexing Section.

Are any CANbus circuit faults present?

YES: Repair and retest system.

NO: Proceed to Step 4.

4. Measure resistance between frame and CANbus circuits.

Is resistance ≥1M ohm?

YES: Proceed to Cause A. NO: Suspect short to frame.

CAUSE A - CANBUS COMMUNICATION FAULT PROCEDURE OR ACTION: NOTE: Perform Step 1 and Step 2 with key in ON position.

NOTE: Connector CJ2 is an eight position connector.

1. Disconnect the tiller card connector CJ2 and measure voltage between connector CJ2, socket 2 and B(-).

Is CAN HI voltage approximately 2.5 Vdc? YES: Proceed to Step 2.

NO: Inspect CAN HI circuit for open or short. If voltage is 0 volts, the CAN HI circuit is shorted to ground or open. If voltage is above 5 volts, the CAN HI circuit is shorted to power.

2. Measure voltage between the tiller card connector CJ2, socket 1 and B(-).

Is CAN LO voltage approximately 2.5 Vdc?

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9030-20-47

Diagnostic Trouble Codes

ELECTRICAL SYSTEM

DTC 30106 (Cont) CANcomm YES: Disconnect battery and proceed to Step 3.

NO: Inspect CAN LO circuit for open or short. If voltage is 0 volts, the CAN LO circuit is shorted to ground or open. If voltage is above 5 volts, the CAN LO circuit is shorted to power.

3. Measure resistance between the tiller card connector CJ2, socket 1 and socket 2.

Is resistance 60 ± 6 ohms?

YES: No communication faults are present, connect battery and proceed to Cause B. NO: If resistance is 120 ohms, the CANbus has an open circuit or a missing or damaged termination resistor.

If resistance is 0 ohms, the CANbus circuits are shorted together.

CAUSE B - TILLER CARD WIRING FAULT PROCEDURE OR ACTION: NOTE: Perform Steps 1 through 4 with key in ON position.

1. Open control handle, observe tiller card assembly.

Is CRS03 connected to Tiller Card JP1?

YES: Proceed to Step 2.

NO: Connect tiller harness to JP1.

2. With control handle open, observe tiller card LCD display and re-key truck.

Does LCD display illuminate?

YES: Proceed to Step 3.

NO: Proceed to Step 4.

3. Continue to observe tiller card LCD display and re-key truck.

Is LCD display properly configured?

YES: Proceed to Cause C. NO: Refer to 2200 SRM 1507 to configure tiller card.

4. Disconnect CRS03 from tiller card JP1. Measure voltage between socket 1 and B(-).

Is voltage same as battery voltage?

YES: Disconnect battery and proceed to Step 5.

NO: Inspect circuit 010 between key switch TS05 and CRS03 for open or short.

5. Measure resistance between the tiller card connector JP1, socket 2 and B(-).

Is resistance ≤1 ohm?

YES: Proceed to Cause C. NO: Inspect ground circuit 101 for open, short, or source of excessive resistance.

CAUSE C - FAULTY HANDLE PROCEDURE OR ACTION: 1. Replace faulty handle. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES

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9030-20-48

ELECTRICAL SYSTEM

Diagnostic Trouble Codes

DTC 30106 (Cont) CANcomm DTC 30106 CANCOMM DIAGRAMS

Control Card END FAULT

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9030-20-49

Diagnostic Trouble Codes

ELECTRICAL SYSTEM

CODES DTC 30201 - Start Up DTC 60211 - Start Up POSSIBLE CAUSE A. B. C. D. E. F.

INCORRECT START UP SEQUENCE CANBUS COMMUNICATION FAULT HANDLE WIRING FAULT TRACTION INTERLOCK SENSOR FAULT TILLER CONTROL CARD FAULT FAULTY TRACTION CONTROLLER NOTE Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK NOTE: Always check battery condition and state of charge before performing electrical troubleshooting. A faulty or low charged battery will cause electrical features to not operate as designed and give incorrect readings while performing electrical tests.

PROCEDURE OR ACTION: 1. Conduct a visual inspection of all connectors/wiring associated with the fault code.

Are any faults detected/observed?

YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical System SRM .

NO: Proceed to Step 2.

2. Re-key the vehicle.

Is the code still present?

YES: Proceed to Cause B. NO: Problem may be intermittent.

CAUSE A - INCORRECT START UP SEQUENCE PROCEDURE OR ACTION: 1. The fault code may occur when the operator commands traction when traction interlock sensor is OFF or if driving tiller arm traveled outside of tiller arm operational range. Refer to Electrical System SRM manual for tiller arm operational range information.

Is fault caused by tiller arm operation?

YES: Clear fault.

NO: Proceed to Cause A. CAUSE B - CANBUS COMMUNICATION FAULT PROCEDURE OR ACTION: NOTE: Perform Step 1 and Step 2 with key in ON position.

1. Measure voltage between connector CPS09 (PC Service Tool connector), socket C and socket A.

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9030-20-50

ELECTRICAL SYSTEM

Diagnostic Trouble Codes

(Cont) Is CAN HI voltage approximately 2.5 Vdc? YES: Proceed to Step 2.

NO: Inspect CAN HI circuit for open or short. If voltage is 0 volts, the CAN HI circuit is shorted to ground or open. If voltage is above 5 volts, the CAN HI circuit is shorted to power.

2. Measure voltage between connector CPS09, socket C and socket B. Is CAN LO voltage approximately 2.5 Vdc? YES: Disconnect battery and proceed to Step 3.

NO: Inspect CAN LO circuit for open or short. If voltage is 0 volts, the CAN LO circuit is shorted to ground or open. If voltage is above 5 volts, the CAN LO circuit is shorted to power.

3. Measure voltage between connector CPS09, socket A and socket B. Is resistance 60 ± 6 ohms?

YES: No communication faults are present, connect battery and proceed to Cause C. NO: If resistance is 120 ohms, the CANbus has an open circuit or a missing or damaged termination resistor.

If resistance is 0 ohms, the CANbus circuits are shorted together.

CAUSE C - HANDLE WIRING FAULT PROCEDURE OR ACTION: NOTE: The CANbus has two 120 ohm termination resistors connected in parallel. One resistor is between the tiller card and the traction controller. The second resistor is connected to the traction controller. With the tiller card and traction controller disconnected from the harness, CANbus resistance is 120 ohms at the harness. Measuring resistance between the traction controller connector CPS01, pins 21 and 34 will measure 120 ohms. When both 120 ohm resistors are correctly connected in parallel, a measurement of 60 ohms is expected.

NOTE: Perform the following Step with key in ON position.

1. Disconnect connector CRP10 and measure voltage between pin 1 and pin 3.

Is voltage same as key switch voltage?

YES: Disconnect the battery and proceed to Step 2.

NO: Inspect circuit 010 for open or short.

2. Measure voltage between CPS01, pin 9 and B(-). Move tiller arm within operational region, ensure interlock LED is illuminated.

Is voltage same as key switch voltage?

YES: Proceed to Cause F. NO: Proceed to Step 3.

3. Disconnect traction controller connector CPS01, tiller harness connector CRP06, and interlock sensor CRP10. Measure resistance between CRP06/pin 6, CRP10/pin 2, CPS01/socket 9.

Is resistance ≤ 1 ohm?

YES: Proceed to Cause D. NO: Inspect circuit 601 for open, shorts or source of excessive resistance.

CAUSE D - TRACTION INTERLOCK SENSOR FAULT PROCEDURE OR ACTION: 1. Remove helmet plate from tiller arm base. Move tiller arm up and down and observe LED light in traction controller interlock sensor.

Does light turn OFF when tiller arm is withing operational region?

YES: Proceed to Cause E. NO: Proceed to Step 2.

2. Measure distance between sensor and helmet plate.

Is helmet plate within specifications?

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9030-20-51

Diagnostic Trouble Codes

ELECTRICAL SYSTEM

(Cont) YES: Replace faulty sensor.

NO: Adjust sensor and torque as needed. Use Electrical System manual for reference.

CAUSE E - TILLER CONTROL CARD FAULT PROCEDURE OR ACTION: 1. Replace tiller control card. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate problem description leading to card replacement.

CAUSE F - FAULTY TRACTION CONTROLLER PROCEDURE OR ACTION: 1. Replace faulty handle. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES

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9030-20-52

ELECTRICAL SYSTEM

Diagnostic Trouble Codes

(Cont)

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9030-20-53

Diagnostic Trouble Codes

ELECTRICAL SYSTEM

(Cont)

END FAULT

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9030-20-54

ELECTRICAL SYSTEM

Diagnostic Trouble Codes

DTC 30227 Stalled POSSIBLE CAUSE A. B. C. D.

ENCODER WIRING FAULT FAULTY TRACTION ENCODER FAULTY TRACTION MOTOR FAULTY TRACTION CONTROLLER NOTE Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK NOTE: Always check battery condition and state of charge before performing electrical troubleshooting. A faulty or low charged battery will cause electrical features to not operate as designed and give incorrect readings while performing electrical tests.

PROCEDURE OR ACTION: 1. Remove cover from truck frame. Inspect transmission and tire for obstructions or binding.

Is object impeding steering motor?

YES: Remove object; clear code and verify repair.

NO: Proceed to Step 2.

NOTE: Use caution when performing the following test. The traction controller and brake will be OFF. 2. With key in OFF position, locate the brake override connectors on left and right side of traction motor. Disconnect CRP04-B and CRP04-A, connect CRP04-B to the electromagnetic brake connector. Move the truck back and forward and move handle side to side.

Does truck move and rotate freely?

YES: Connect CRP04-B AND CRP04-A and proceed to Step 3.

NO: Inspect transmission.

3. Conduct a visual inspection of all connectors/wiring associated with the fault code.

Are any faults detected/observed?

YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical System SRM .

NO: Proceed to Step 4.

4. Re-key the vehicle.

Is the code still present?

YES: Proceed to Cause A. NO: Problem may be intermittent.

CAUSE A - ENCODER WIRING FAULT PROCEDURE OR ACTION: NOTE: Perform Step 1 with key in ON position.

1. Disconnect the traction motor encoder connector CPS03 and measure voltage between socket 1 and B(-).

Is voltage 5 ± 0.5 Vdc? YES: Proceed to Step 2.

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9030-20-55

Diagnostic Trouble Codes

ELECTRICAL SYSTEM

DTC 30227 (Cont) Stalled NO: Inspect circuit 250 for open or short.

2. Measure resistance between the encoder connector CPS03, socket 4 and B(-).

Is resistance <1 ohm?

YES: Disconnect battery and proceed to Step 3.

NO: Inspect ground circuit 102 for open or short.

3. Disconnect traction controller connector CPS01 and measure resistance between socket 32 and the encoder connector CPS03, socket 3.

Is resistance <1 ohm?

YES: Proceed to Step 4.

NO: Inspect signal circuit 578 for open or source of excessive resistance.

4. Measure resistance between socket 31 of the traction controller connector CPS01 and socket 2 of the encoder connector CPS03.

Is resistance <1 ohm?

YES: Proceed to Cause C. NO: Inspect signal circuit 577 for open or source of excessive resistance.

CAUSE B - FAULTY TRACTION ENCODER PROCEDURE OR ACTION: 1. Measure voltage between sockets 31/32 and B(-) of the traction connector CPS01; operate traction motor.

Was voltage present?

YES: Proceed to Cause D. NO: Replace encoder. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate problem description leading to controller replacement.

CAUSE C - FAULTY TRACTION MOTOR PROCEDURE OR ACTION: NOTE: Disconnect battery.

1. Measure continuity between the motor terminals U and V. Is continuity present?

YES: Proceed to Step 2.

NO: Repair or replace faulty motor.

2. Measure continuity between the motor terminals U and W. Is continuity present?

YES: Proceed to Step 3.

NO: Repair or replace faulty motor.

3. Measure continuity between the motor terminals W and V. Is continuity present?

YES: Proceed to Cause D. NO: Repair or replace faulty motor.

CAUSE D - FAULTY TRACTION CONTROLLER PROCEDURE OR ACTION: 1. If no faults are found, replace controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate problem description leading to controller replacement.

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9030-20-56

ELECTRICAL SYSTEM

Diagnostic Trouble Codes

DTC 30227 (Cont) Stalled END POSSIBLE CAUSES DTC 30227 STALLED DIAGRAMS

Traction Motor END FAULT

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9030-20-57

Diagnostic Trouble Codes

ELECTRICAL SYSTEM

DTC 30232 Software POSSIBLE CAUSE A. INCORRECT PARAMETER/SOFTWARE INSTALLATION B. FAULTY TRACTION CONTROLLER COMPONENT OPERATIONAL CHECK NOTE: Always check battery condition and state of charge before performing electrical troubleshooting. A faulty or low charged battery will cause electrical features to not operate as designed and give incorrect readings while performing electrical tests.

PROCEDURE OR ACTION: 1. Conduct a visual inspection of all connectors/wiring associated with the fault code.

Are any faults detected/observed?

YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical System SRM .

NO: Proceed to Step 2.

2. Re-key the vehicle.

Is the code still present?

YES: Proceed to Cause A. NO: Fault may be intermittent.

CAUSE A - INCORRECT PARAMETER/SOFTWARE INSTALLATION PROCEDURE OR ACTION: 1. Connect PC Service Tool and observe Truck Report. Connect to FST, download software and CDF file. Once download is complete, rekey the truck.

Is the code still present?

YES: Clear error fault code from history. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate problem description of service provided.

NO: Proceed to Cause B. CAUSE B - FAULTY TRACTION CONTROLLER PROCEDURE OR ACTION: 1. If no faults are found, replace controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES END FAULT

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9030-20-58

ELECTRICAL SYSTEM

Diagnostic Trouble Codes

DTC 30247 Parameter POSSIBLE CAUSE A. INCORRECT PARAMETER/SOFTWARE INSTALLATION B. FAULTY TRACTION CONTROLLER COMPONENT OPERATIONAL CHECK NOTE: Always check battery condition and state of charge before performing electrical troubleshooting. A faulty or low charged battery will cause electrical features to not operate as designed and give incorrect readings while performing electrical tests.

PROCEDURE OR ACTION: 1. Conduct a visual inspection of all connectors/wiring associated with the fault code.

Are any faults detected/observed?

YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical System SRM .

NO: Proceed to Step 2.

2. Re-key the vehicle.

Is the code still present?

YES: Proceed to Cause A. NO: Fault may be intermittent.

CAUSE A - INCORRECT PARAMETER/SOFTWARE INSTALLATION PROCEDURE OR ACTION: 1. Connect PC Service Tool and observe Truck Report. Connect to FST, download software and CDF file. Once download is complete, rekey the truck.

Is the code still present?

YES: Clear error fault code from history. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate problem description of service provided.

NO: Proceed to Cause B. CAUSE B - FAULTY TRACTION CONTROLLER PROCEDURE OR ACTION: 1. If no faults are found, replace controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES END FAULT

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9030-20-59

Diagnostic Trouble Codes

ELECTRICAL SYSTEM

DTC 30248 Low Temp POSSIBLE CAUSE A. WIRING FAULT B. FAULTY TRACTION CONTROLLER COMPONENT OPERATIONAL CHECK NOTE: Always check battery condition and state of charge before performing electrical troubleshooting. A faulty or low charged battery will cause electrical features to not operate as designed and give incorrect readings while performing electrical tests.

PROCEDURE OR ACTION: 1. Conduct a visual inspection of all connectors/wiring associated with the fault code.

Are any faults detected/observed?

YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical System SRM .

NO: Proceed to Step 2.

2. Re-key the vehicle.

Is the code still present?

YES: Proceed to .

NO: Fault may be intermittent.

3. Remove truck from austere environment and turn key to ON position. The system will recover once truck is able to achieve an internal temperature of -30°C (-22°F) or higher.

Did system record and code reset?

YES: Instruct operator on thermal management.

NO: Proceed to Cause A. CAUSE A - WIRING FAULT PROCEDURE OR ACTION: 1. Perform Voltage Checks as indicated in the Basic Electrical Troubleshooting section.

Is the code still present?

YES: Clear error log. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate problem description of service provided.

NO: Proceed to Step 2.

2. Disconnect CPS01 and CPS02. Measure resistance between CPS01, socket 8 and CPS02, socket 1.

Is resistance ≤ 1 ohm?

YES: Connect CPS01 and proceed to Step 3.

NO: Inspect circuit 367 for open, short, or source of excessive resistance.

3. Measure resistance between CPS02, socket 2 and B(-).

Is resistance ≤ 1 ohm?

YES: Proceed to Cause B. NO: Inspect circuit 101 for open, short, or source of excessive resistance.

CAUSE B - FAULTY TRACTION CONTROLLER PROCEDURE OR ACTION: 1. If no faults are found, replace controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate problem description leading to controller replacement.

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9030-20-60

ELECTRICAL SYSTEM

Diagnostic Trouble Codes

DTC 30248 (Cont) Low Temp END POSSIBLE CAUSES END FAULT

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9030-20-61

Diagnostic Trouble Codes

ELECTRICAL SYSTEM

CODES DTC 60050 - EmerRevr DTC 60210 - EmerRevr POSSIBLE CAUSE A. B. C. D.

START UP SEQUENCE BELLY SWITCH SEQUENCE CONTROLLER WIRING FAULT FAULTY TILLER CONTROL CARD NOTE Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK NOTE: Always check battery condition and state of charge before performing electrical troubleshooting. A faulty or low charged battery will cause electrical features to not operate as designed and give incorrect readings while performing electrical tests.

PROCEDURE OR ACTION: 1. Conduct a visual inspection of all connectors/wiring associated with the fault code.

Are any faults detected/observed?

YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical System SRM .

NO: Proceed to Step 2.

2. Re-key the vehicle.

Is the code still present?

YES: Proceed to Step 3.

NO: Problem may be intermittent.

3. Using the PC Service Tool, locate input diagnostics and view belly switch input.

Is belly switch operational?

YES: fault may be intermittent. Inspect belly switch for damage.

NO: Proceed to Cause A. CAUSE A - START UP SEQUENCE PROCEDURE OR ACTION: 1. This fault code will occur if operator commands traction while traction interlock sensor is off or if operator is operating tiller arm outside of operational range. Reference the Electrical System SRM to identify tiller arm operational range and to verify actual cause of fault.

Was fault due to interlock or tiller arm operation?

YES: Clear fault.

NO: Proceed to Cause B. CAUSE B - BELLY SWITCH SEQUENCE PROCEDURE OR ACTION: 1. Reference the Electrical System SRM as this fault code will occur if:

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9030-20-62

ELECTRICAL SYSTEM

Diagnostic Trouble Codes

(Cont) •

The emergency reverse switch was activated when operator initiated a traction command

•

The emergency reverse switch was activated with the tiller arm outside of the operational range

•

The traction is activated by throttle command while truck was in emergency reverse traction mode.

Was fault due to one or more of the above?

YES: Clear fault.

NO: Proceed to Cause C. CAUSE C - CONTROLLER WIRING FAULT PROCEDURE OR ACTION: NOTE: Perform Step 1 with key in ON position.

1. Measure voltage between tiller card connector CRR03 and measure voltage between pin 1 and pin 2.

Is voltage same as key switch voltage?

YES: Proceed to Step 2.

NO: Inspect circuit 010 for open or short.

2. Measure voltage between pin 22 and B(-) of connector CPS01. Perform test with tiller arm up and emergency reverse button depressed.

Is the voltage same as key switch voltage YES: Disconnect battery and proceed to Step 3.

NO: Proceed to Cause D. 3. Measure resistance between CPS01, socket 22 and CRR03, socket 05.

Is resistance ≤ 1 ohm?

YES: Proceed to Cause D. NO: Inspect circuit 602 for open, short, or source of excessive resistance.

CAUSE D - FAULTY TILLER CONTROL CARD PROCEDURE OR ACTION: 1. If no faults are found, replace tiller control card. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES

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9030-20-63

Diagnostic Trouble Codes

ELECTRICAL SYSTEM

(Cont) DIAGRAMS

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9030-20-64

ELECTRICAL SYSTEM

Diagnostic Trouble Codes

(Cont)

Emergency Reverse END FAULT

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9030-20-65

NOTES

9030-20-66

TECHNICAL PUBLICATIONS 9000 SRM 1671

1/15 (12/14)(10/14)(4/14)(1/14)

DIAGRAMS P2.0 [A290]; W45ZHD [A419]

PART NO. 4035869

8000 SRM 1512

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR •

• • • • • • • • • • • • • •

The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the product. Updated technical service information may be available from your local authorized Hyster® dealer. Service Manuals provide general guidelines for maintenance and service and are intended for use by trained and experienced technicians. Failure to properly maintain equipment or to follow instructions contained in the Service Manual could result in damage to the products, personal injury, property damage or death.

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 when making 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.

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury and property damage.

On the lift truck, the WARNING symbol and word are on orange background. The CAUTION symbol and word are on yellow background.

Table of Contents

TABLE OF CONTENTS General Notes .......................................................................................................................................................... 1 Diagrams, Schematics or Arrangements................................................................................................................ 2 Figure 1. Schematic/Wiring Diagram Pallet Truck........................................................................................... 2 Figure 2. Schematic/Wiring Diagram Premium Walkie....................................................................................5 This section is for the following models: (P2.0) [A290]; (W45ZHD) [A419]

©2015 HYSTER COMPANY

i

"THE QUALITY KEEPERS" HYSTER APPROVED PARTS

8000 SRM 1512

General Notes

General Notes All parts are shown in the normal position for the following conditions: •

Unit stopped.

•

Operator is off the unit.

•

With battery disconnected.

•

Reverse is travel in the direction of the forks.

•

Chain lines indicate EE enclosure.

•

Broken lines are for option only.

•

All unused terminals and connectors must be secure to a main wire harness branch.

•

All connectors are drawn from front view and are enlarged for clarity.

1

General Notes

8000 SRM 1512

Figure 1. Schematic/Wiring Diagram Pallet Truck (Sheet 1 of 3)

2

8000 SRM 1512

Diagrams, Schematics or Arrangements

Figure 1. Schematic/Wiring Diagram Pallet Truck (Sheet 2 of 3)

3

Diagrams, Schematics or Arrangements

Figure 1. Schematic/Wiring Diagram Pallet Truck (Sheet 3 of 3)

4

8000 SRM 1512

8000 SRM 1512

Diagrams, Schematics or Arrangements

Figure 2. Schematic/Wiring Diagram Premium Walkie (Sheet 1 of 6)

5

Diagrams, Schematics or Arrangements

Figure 2. Schematic/Wiring Diagram Premium Walkie (Sheet 2 of 6)

6

8000 SRM 1512

8000 SRM 1512

Diagrams, Schematics or Arrangements

Figure 2. Schematic/Wiring Diagram Premium Walkie (Sheet 3 of 6)

7

Diagrams, Schematics or Arrangements

Figure 2. Schematic/Wiring Diagram Premium Walkie (Sheet 4 of 6)

8

8000 SRM 1512

8000 SRM 1512

Diagrams, Schematics or Arrangements

Figure 2. Schematic/Wiring Diagram Premium Walkie (Sheet 5 of 6)

9

Diagrams, Schematics or Arrangements

Figure 2. Schematic/Wiring Diagram Premium Walkie (Sheet 6 of 6)

10

8000 SRM 1512

TECHNICAL PUBLICATIONS 8000 SRM 1512

1/15 (1/14)(12/13)(7/13)(6/11)

MASTER DRIVE UNIT P2.0 [A290]; W45ZHD [A419]

PART NO. 4035860

0630 SRM 1503

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR •

• • • • • • • • • • • • • •

The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the product. Updated technical service information may be available from your local authorized Hyster® dealer. Service Manuals provide general guidelines for maintenance and service and are intended for use by trained and experienced technicians. Failure to properly maintain equipment or to follow instructions contained in the Service Manual could result in damage to the products, personal injury, property damage or death.

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 when making 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.

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury and property damage.

On the lift truck, the WARNING symbol and word are on orange background. The CAUTION symbol and word are on yellow background.

Table of Contents

TABLE OF CONTENTS General .....................................................................................................................................................................1 Safety Precautions ...................................................................................................................................................2 Drive Tire .................................................................................................................................................................3 Remove ................................................................................................................................................................ 3 Install ...................................................................................................................................................................3 Master Drive Unit ................................................................................................................................................... 3 Remove ................................................................................................................................................................ 3 Steering Bearing .............................................................................................................................................5 Install ...................................................................................................................................................................5 Troubleshooting .......................................................................................................................................................6 This section is for the following models: P2.0 [A290]; (W45ZHD) [A419]

©2015 HYSTER COMPANY

i

"THE QUALITY KEEPERS" HYSTER APPROVED PARTS

0630 SRM 1503

General

General The master drive unit (MDU) includes the drive motor, brake assembly, drive unit, and drive tire and wheel assembly.

The drive motor is vertically mounted on top of the MDU. In some instances, it may be necessary to remove the drive motor to work on the MDU. In other cases, the drive motor may remain attached to the MDU while repairs are made. The complete MDU, including the motor, may also be removed if necessary. Determine the extent of disassembly required before proceeding with any repairs.

NOTE: The drive unit bearings are lubricated by the drive unit gear oil and do not require packing with grease.

CAUTION

The MDU is vertically installed in the truck and allows an effective utilization of space. The compact, one-piece housing is made of high-duty nodular iron; thus having a high rigidity and optimum guiding precision. This allows a fully integrated bearing of the helical spur gear stage with a very high running smoothness; i.e., no drive pinion on the motor shaft of the electric motor.

The MDU consists of two ratio steps. Gear ratio 1 is designed as helical spur gear stage and permanently integrated in the housing. Gear ratio 2 is designed as Gleason bevel gearing of the hypoid type with offset bevel pinion shaft.

NOTE: There are no serviceable parts within the drive unit. If repair of the master drive unit is required, the entire assembly must be replaced.

Some of the hardware used on the MDU and traction motor is metric. Use the correct tools to avoid damage.

1

Safety Precautions

0630 SRM 1503

Safety Precautions WARNING Put blocks under each side of the truck under the drive unit frame. Position blocks on both sides of the load wheels. The blocks must prevent the motorized hand truck from falling and causing injury or damage.

3. Discharge the capacitors in the controllers by connecting a 200-ohm, 2-watt resistor across the controller's B+ and B- terminals using insulated jumper wires. See Figure 1. DO NOT short across the motor controller terminals with a screwdriver or a jumper wire. Remove the 200-ohm, 2-watt resistor before reconnecting the battery.

WARNING The capacitor in the transistor controller can hold an electrical charge after the battery is disconnected. To prevent electrical shock and personal injury, discharge the capacitor before inspecting or repairing any component in the MDU compartment. Wear safety glasses. Make certain the battery has been disconnected. DO NOT use a screwdriver to make a short circuit across the B+ and Bterminals of the transistor controller.

WARNING To avoid personal injury and prevent electrical shock, perform the following steps before performing any troubleshooting or adjustments, and before connecting or disconnecting a handset or Personal Computer.

WARNING To avoid controller damage, always disconnect the battery. Discharge the capacitor and never put power to the controller with any power wire disconnected. Never short any controller terminal or motor terminal to battery. Make sure to use proper procedure when servicing the controller.

1. Block the lift truck so that the drive wheel is off the floor. See: •

Periodic Maintenance 8000SRM1510 for lift truck model A290

•

Periodic Maintenance 8000SRM1666 for lift truck model A419

2. Turn the key switch to the OFF position and disconnect the battery.

2

1.

2.

3.

4.

5.

CONTROLLER POSITIVE CONNECTION INSULATED JUMPER WIRES 200-OHM, 2-WATT RESISTOR NEGATIVE CONNECTION Figure 1. Discharging Controller

0630 SRM 1503

Drive Tire

Drive Tire REMOVE

3. Loosen and remove the five lug nuts securing the drive tire and wheel assembly to the axle shaft.

WARNING Block each side of the truck under the drive unit frame. Position blocks on both sides of the load wheels to prevent the truck from falling.

4. Remove the drive tire and wheel assembly.

1. Block the lift truck so the drive tire is off the floor. Refer to the section;

1. Mount the drive tire and wheel assembly on the axle shaft.

•

Periodic Maintenance 8000SRM1510 for lift truck model A290

•

Periodic Maintenance 8000SRM1666 for lift truck model A419

INSTALL

2. Install lug nuts. Tighten lug nuts to 120 N•m (88 lbf ft).

3. Remove blocks and lower the lift truck to the floor. Reconnect the battery.

2. Turn the key switch to the OFF position and disconnect battery.

Master Drive Unit REMOVE The master drive unit (MDU) has five main components: the traction motor, brake, steering control handle, drive unit, and drive tire and wheel assembly.

Separate parts of the MDU can be removed without removing the complete MDU. It is not necessary to perform each step of the entire procedure to remove some parts of the MDU. The procedure has steps to remove and disassemble the complete MDU. Read the entire procedure first and perform only the steps necessary to make the required repairs.

WARNING Cleaning solvents can be flammable, toxic, and can cause skin irritation. Wear protective gear when handling solvents and always follow the recommendations of the manufacturer.

WARNING Put blocks under each side of the truck under the MDU frame. Position blocks on both sides of the load wheels. The blocks must prevent the lift truck from falling and causing personal injury or property damage.

NOTE: Insure the truck is blocked high enough to remove the drive unit from below the truck frame.

1. Raise the drive tire off the floor. Block the lift truck. Refer to the section: •

Periodic Maintenance 8000SRM1510 for lift truck model A290

•

Periodic Maintenance 8000SRM1666 for lift truck model A419

WARNING Always disconnect the battery connector so that the connector is completely free before repairing the brake system. If the connector is not completely free, it can reconnect the battery. Tag the connector - DO NOT CONNECT. 2. Turn the key switch to the OFF position and disconnect the battery connector.

3. Remove the drive unit compartment cover to access the MDU. Refer to AC Motor Repair 0620SRM1513.

4. Discharge the capacitors. Refer to Safety Precautions in this section.

5. Remove the lug nuts and remove the drive tire and wheel. See Figure 2.

3

Master Drive Unit

0630 SRM 1503 8. Tag and disconnect the wiring from the steering tiller to the lift truck.

9. Support the steering tiller and remove the four capscrews and washers securing the tiller to the master drive unit. See Figure 3.

1. TILLER MOUNTING BOLTS 2. TILLER MOUNT 3. TILLER ASSEMBLY Figure 3. Tiller Mounting 10. Remove the tiller from the lift truck.

1.

2.

3.

4.

5.

6.

BRAKE MOTOR DRIVE UNIT DRIVE TIRE LUG NUTS MDU UNIT Figure 2. MDU Assembly

6. Identify and tag all wires and cables connected to MDU for later installation.

7. Disconnect all wires and cables connected to MDU and the harness clamps on the drive motor.

4

11. Remove the traction motor and brake as a single assembly. a. Remove the four screws and lockwashers retaining the drive motor. See Figure 4. b. Attach a sling and an over head hoist to the drive motor. c. Lift the drive motor and brake assembly from the drive unit. d. Remove the brake assembly from the traction motor if necessary. Refer to the section Brakes 1800SRM1505.

0630 SRM 1503

Master Drive Unit

1. CAPSCREWS Figure 5. Steering Bearing

1. MOUNTING SCREWS Figure 4. Motor Mounting

WARNING To avoid personal injury, keep the MDU supported at all times.

12. Use a jack to support the drive unit. Remove the capscrews attaching the drive unit to the steer bearing.

13. Remove the drive unit from the truck and place on a clean work bench.

Steering Bearing NOTE: It is necessary to remove the master drive unit, before the steering bearing can be removed.

2. Align the eight mounting holes in the bearing with the holes in the casting.

3. Install the eight capscrews to retain the bearing to the casting. Torque the mounting capscrews to 23 N•m (17 lbf ft).

4. Use a jack to position the drive unit.

5. Align the drive unit with the screw holes in the steering bearing and install the capscrews attaching the drive unit to the bearing. Tighten all of the capscrews to 23 N•m (17 lbf ft).

NOTE: The traction motor is easily installed AFTER the MDU has been mounted to the frame of the lift truck.

6. Install the traction motor:

1. From underneath the master drive unit mounting casting, remove the eight capscrews retaining the steering bearing to the mounting casting. See Figure 5.

a. Apply a light coat of moly paste lubricant Hyster® part no. 339068 to the traction motor splines.

2. Carefully use a pry bar or other device to remove the steering bearing from the casting.

b. Position traction motor over drive unit using an overhead lifting device and sling. Lower motor slowly to check for proper entry into the seal and to align pins.

INSTALL

c. Secure motor to drive unit.

WARNING To avoid personal injury when installing the drive unit in the lift truck, keep the drive unit supported at all times.

1. Install the steering bearing on the mounting casting.

(1)

Install the four capscrews to secure motor as removed.

(2)

Torque capscrews to 17 ±1 N•m (150 ±9 lbf in).

5

Master Drive Unit

0630 SRM 1503

CAUTION

10. Install the steer components as removed. See the section Steering Mechanism 1600SRM1504.

To prevent damage to the brake assembly always follow the special procedure for brake adjustment when adjusting the brake.

11. Lower the truck to the floor.

7. Install and adjust the brake if removed. Refer to the section Brakes 1800SRM1505.

12. Connect the battery and turn the key switch to the ON position.

8. Mount the drive wheel on the axle shaft and install lug nuts. Tighten lug nuts to 120 N•m (88 lbf ft).

13. Test the operation of the truck.

14. Install the drive unit compartment cover and return truck to service.

9. Connect the motor wires and cables. Attach the harness clamps.

Troubleshooting PROBLEM Lift truck will not move.

POSSIBLE CAUSE

PROCEDURE OR ACTION

Motor not operating.

Check wiring or repair motor.

Check battery, battery connection, and truck fuses.

Damaged gears or bearings.

Replace drive unit.

Dry or damaged bearings.

Replace drive unit.

Worn or damaged gears.

Replace drive unit.

Oil leakage at upper part in motor compartment.

Motor seal defective.

Replace motor seal.

Oil leakage at housing cover.

Housing cover not sealed to housing.

Clean, seal, and tighten housing cover capscrews to correct torque.

Capscrews not sealed or not tightened to correct torque.

Tighten housing cover capscrews to correct torque, 32 N•m (24 lbf ft).

MDU makes noise.

6

TECHNICAL PUBLICATIONS 0630 SRM 1503

3/15 (12/13)(6/11)

ELECTRICAL SYSTEM P2.0 [A290]; W45ZHD [A419]

PART NO. 4035865

2200 SRM 1508

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR •

• • • • • • • • • • • • • •

The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the product. Updated technical service information may be available from your local authorized Hyster® dealer. Service Manuals provide general guidelines for maintenance and service and are intended for use by trained and experienced technicians. Failure to properly maintain equipment or to follow instructions contained in the Service Manual could result in damage to the products, personal injury, property damage or death.

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 when making 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.

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury and property damage.

On the lift truck, the WARNING symbol and word are on orange background. The CAUTION symbol and word are on yellow background.

Table of Contents

TABLE OF CONTENTS General .....................................................................................................................................................................1 Special Precautions ................................................................................................................................................. 2 Discharging the Capacitors ................................................................................................................................ 2 Electrical System Checks ........................................................................................................................................3 Safety Precautions .............................................................................................................................................. 3 Repairs ..................................................................................................................................................................... 5 Controller, Replace ..............................................................................................................................................5 Remove ............................................................................................................................................................ 5 Install .............................................................................................................................................................. 5 Pump Contactor Coil, Check .............................................................................................................................. 6 Pump Contactor, Replace ................................................................................................................................... 6 Contactor Tips, Replace ......................................................................................................................................6 Remove ............................................................................................................................................................ 7 Install .............................................................................................................................................................. 7 Fuses ........................................................................................................................................................................ 8 Disconnect Switch Battery.....................................................................................................................................10 Disconnect Switch, Check .................................................................................................................................10 Remove Disconnect Switch ...............................................................................................................................10 Install Disconnect Switch ................................................................................................................................. 10 Main Contactor Coil, Check ............................................................................................................................. 10 Horn ....................................................................................................................................................................... 11 Remove .............................................................................................................................................................. 11 Install .................................................................................................................................................................11 Brake and Interlock Sensor .................................................................................................................................. 11 Remove .............................................................................................................................................................. 11 Install .................................................................................................................................................................12 Check ................................................................................................................................................................. 12 Steer Reduction Sensor .........................................................................................................................................13 Remove .............................................................................................................................................................. 13 Install .................................................................................................................................................................13 Height Limit .......................................................................................................................................................... 14 Control Handle ...................................................................................................................................................... 14 Disassemble .......................................................................................................................................................14 Control Handle Card .........................................................................................................................................14 Configure .......................................................................................................................................................14 Calibrate ........................................................................................................................................................16 Assemble ............................................................................................................................................................17 Charger and Convenience Port .............................................................................................................................19 Remove .............................................................................................................................................................. 19 Install .................................................................................................................................................................20 BDI Display ........................................................................................................................................................... 21 Remove .............................................................................................................................................................. 21 Install .................................................................................................................................................................21 ACCUSENSE Battery Charger ............................................................................................................................ 22 Charger Mode/Battery Type Selection .............................................................................................................22 Changing Mode Setting ................................................................................................................................24 Convenience Port .............................................................................................................................................. 24 General ..........................................................................................................................................................24 LED Status Display ......................................................................................................................................25 Charging ........................................................................................................................................................25

©2015 HYSTER COMPANY

i

Table of Contents

TABLE OF CONTENTS (Continued) Troubleshooting .................................................................................................................................................26 General ..........................................................................................................................................................26 Error Modes .................................................................................................................................................. 27 A.C. Convenience Port Accessory (Optional) .......................................................................................... 28 Battery Pack Troubleshooting ..................................................................................................................... 28 This section is for the following models: P2.0 [A290]; (W45ZHD) [A419]

ii

2200 SRM 1508

General

General WARNING DO NOT make repairs or adjustments unless you have both authorization and training. Repairs and adjustments that are not correct can create a dangerous operating condition. DO NOT operate a lift truck that needs repairs. Report the need for repairs to your supervisor immediately. If repair is necessary, put a DO NOT OPERATE tag on the control handle. Remove the key from the key switch.

This manual describes the electrical system used on the motorized hand lift truck. Procedures are outlined for the maintenance, adjustment, and repair that may be required when servicing this lift truck. See Figure 1.

1. BATTERY DISCONNECT SWITCH AND MAIN CONTACTOR 2. DISPLAY 3. FUSE 4. KEY SWITCH 5. CONTROLLER 6. BRAKE 7. TRACTION MOTOR 8. HYDRAULIC MOTOR 9. PUMP CONTACTOR 10. HORN 11. CHARGER CONVENIENCE PORT 12. CHARGER Figure 1. Drive Unit Compartment

1

Special Precautions

2200 SRM 1508

Special Precautions DISCHARGING THE CAPACITORS WARNING The capacitor in the controller can hold an electrical charge after the battery is disconnected. To prevent electrical shock and personal injury, discharge the capacitor before inspecting or repairing any component. Wear safety glasses. Make certain the battery has been disconnected. DO NOT use a screwdriver to discharge the traction motor controller.

WARNING To avoid personal injury and prevent electrical shock, perform the following steps before performing any troubleshooting or adjustments, and connecting or disconnecting a handset or PC.

CAUTION To avoid controller damage, always disconnect the battery. Discharge the capacitor and never put power to the controller with any power wire disconnected. Never short any controller terminal or motor terminal to battery. Make sure to use proper procedures when servicing the controller.

1. Move the truck to a safe, level area. Turn the key switch to the OFF position and disconnect the battery.

2. Remove the drive unit compartment cover to access the drive unit compartment.

3. Discharge the capacitor in the controller by connecting a 200-ohm, 2-watt resistor across the controllers B+ and B− terminals using insulated jumper wires. See Figure 2. DO NOT short across the motor controller terminals with a screwdriver or jumper wire.

2

1.

2.

3.

4.

5.

CONTROLLER POSITIVE CONNECTION INSULATED JUMPER WIRES 200-OHM, 2-WATT RESISTOR NEGATIVE CONNECTION Figure 2. Discharging the Capacitors

2200 SRM 1508

Electrical System Checks

Electrical System Checks WARNING Disconnect the battery before opening the compartment cover or inspecting or repairing the electrical system. If a tool causes a short circuit, the high current flow from the battery can cause personal injury or property damage.

The capacitor in the transistor controller can hold an electrical charge after the battery is disconnected. To prevent electrical shock and personal injury, discharge the capacitor before inspecting or repairing any component in the drive unit compartment. Wear safety glasses. Make certain the battery has been disconnected.

All checks, adjustments, and repairs in the drive unit compartment are done with the compartment cover removed. Remove the drive unit compartment cover for access to the electrical components. See Accessing the Drive Unit Compartment in AC Motor Repair 0620SRM1513.

SAFETY PRECAUTIONS WARNING Some checks require the battery to be reconnected. DO NOT connect the battery until the procedure tells you to do so. Make sure the drive wheel is raised to prevent truck movement and possible injury. Raise the drive wheel. The blocks must prevent the lift truck from falling and causing personal injury or property damage.

CAUTION To avoid controller damage, always disconnect the battery before disconnecting any cables from the controller. Discharge the capacitor, and never put power to the controller with any power wire disconnected. Never short any controller terminal or motor terminal to the battery. Make sure to use proper procedure when servicing the controller.

1. Block lift truck so the drive tire is raised slightly off the floor to prevent unexpected movement when making checks.

2. Turn the key switch to the OFF position and disconnect the battery.

3. Discharge the capacitors. See Special Precautions in this section.

NOTE: These checks require a volt-ohmmeter with a meter movement. Most digital meters will not operate correctly for some of these checks. Specific checks require additional equipment.

NOTE: The correct meter polarity is necessary for the checks. The voltage checks are made between the point indicated in Table 1 and battery negative.

Connect the meter negative to battery negative.

NOTE: The battery does not have to be removed to check the specific gravity.

4. Using a hydrometer, check the specific gravity of the battery. If the specific gravity is less than 1.260, the battery is not fully charged or is damaged. A fully-charged battery has a specific gravity of 1.270 to 1.290. A discharged battery has a specific gravity of approximately 1.165.

5. The electric lift truck has a two-wire system.

The frame must not be a common electrical path. Check for 50,000 ohms or more between each battery terminal and a clean connection on the frame. Remove any circuit paths between the controller and the frame of the lift truck, such as a dirty battery case. Carbon dust in a motor or other parts can cause a circuit path. Check for additional equipment that may cause a circuit path to the frame.

6. Check for voltage between each terminal of the connector that fastens to the battery and a clean connection on the frame. Normally, there is small voltage (less than 30 percent of the battery voltage) between the battery and the frame, even though the resistance is very high.

A higher voltage can indicate a dirty battery or a damaged battery. Clean the battery and battery compartment as necessary.

7. Visually check for parts or wires that are loose or damaged.

NOTE: Make an identification of any wires before you disconnect them. The wires must be reconnected correctly after checks or repairs.

3

Electrical System Checks

2200 SRM 1508

Table 1. Voltage Checks LIFT TRUCK WILL NOT MOVE IN EITHER DIRECTION. NO FAULT IS DISPLAYED ON THE CONTROLLER. Possible Causes: 1. Battery not connected.

2. Control fuse is damaged.

3. Key switch or brake switch is damaged.

4. Transistor controller connector unplugged.

5. Transistor controller is damaged.

1. Check for battery voltage on the bat- →→ 0 tery side of control fuse.

--

1.01 Battery voltage at control fuse.

Check for open control fuse.

| | -→

1. Check for battery voltage at control 1 fuse terminal of key switch.

→→ --

1.02 No battery voltage at control fuse. Connect battery or check wiring between battery and fuse.

1.1.1

Battery voltage at key switch. Check for damaged key switch. Check connector.

| | -→ 1. Key switch closed. Brake switch 3 closed. Check for battery voltage at B+ terminal of transistor controller.

1.1.2 No voltage at key switch. Wire to key switch or connections is damaged.

1.3.1 Battery voltage at B+ terminal. Check fault code. If no fault code, possible damaged control handle card.

→→ -| | -→

4

1.3.2 No voltage at B+ terminal. Check B- terminal. Check fault code.

2200 SRM 1508

Repairs

Repairs WARNING DO NOT make repairs or adjustments unless you have been properly trained and authorized to do so. Improper repairs and adjustments can create dangerous operating conditions. DO NOT operate a lift truck that needs repairs. Report the need for repairs to your supervisor immediately. If repair is necessary, attach a DO NOT OPERATE tag to the control handle and disconnect the battery.

•

Periodic Maintenance 8000SRM1666 for lift truck model A419

- How to Put a Lift Truck on Blocks. The blocks must prevent the lift truck from falling and causing personal injury or property damage.

NOTE: Although the controller is factory programmed, any custom parameters must be uploaded or re-entered into the controller when replacing. See the section AC Motor Controller 2200SRM1507.

Disconnect the battery and separate the connector before opening the drive unit compartment cover or inspecting or repairing the electrical system. If a tool causes a short circuit, the high current flow from the battery can cause personal injury or property damage.

DO NOT replace the controller until you have thoroughly checked all other electrical components and are sure the controller is malfunctioning. For the following procedures, refer to Figure 3.

The capacitor in the controller can hold an electrical charge after the battery is disconnected. To prevent electrical shock and personal injury, discharge the capacitor before inspecting or repairing any component in the drive unit compartment.

See Special Precautions in this section.

1. Move the truck to a safe, level location. Turn the key switch to the OFF position, disconnect the battery, and block the drive tire to prevent unexpected movement.

All checks, adjustments, and repairs in the drive unit compartment are done with the compartment cover removed. Remove the drive unit compartment cover for access to the electrical components and discharge the capacitor.

CONTROLLER, REPLACE WARNING Some checks require the battery to be connected.

DO NOT connect the battery until the procedure tells you to do so. Make sure the drive wheel is raised to prevent movement and possible injury.

Raise the drive wheel. See the section •

Periodic Maintenance 8000SRM1510 for lift truck model A290

Remove

2. Remove the drive unit compartment cover. Refer to AC Motor Repair 0620SRM1513, Accessing the Drive Unit Compartment.

3. Discharge the capacitor. See Special Precautions in this section.

4. Tag and disconnect wires from the controller.

5. Remove the mounting screws and remove controller.

Install 1. Install replacement controller on lift truck using mounting hardware.

2. Connect wires and cables to the proper terminals as identified during the removal procedure.

5

Repairs 3. Connect battery, turn the key switch to the ON position, and turn parking brake to the OFF position.

4. Test for proper operation.

5. Install the drive unit compartment cover.

2200 SRM 1508

PUMP CONTACTOR COIL, CHECK Disconnect coil wires. Test contactor coil using an ohmmeter to measure the resistance. The coil should read 55 ohms ±10%. Remove and replace contactor if resistance readings indicate a short circuit in both directions or if there is an open circuit in both directions. Make sure coil wires are connected to the proper terminals.

NOTE: The contactor contains no serviceable parts and must be replaced as a complete assembly.

PUMP CONTACTOR, REPLACE NOTE: Make an identification of any wires before disconnecting them. The wires must be connected correctly after checks or repairs.

Make sure battery is disconnected and capacitor in controller is discharged. For the correct procedure to discharge the controller, refer to Special Precautions. Make an identification of the wires and cables, and disconnect them from the contactor assembly. Remove mounting screws and replace contactor assembly. Install wires and cables as removed.

CONTACTOR TIPS, REPLACE CAUTION All contactor tips must be replaced at the same time if any need replacing.

NOTE: If both the contactor tips and the coil will be replaced, replace complete contactor as described in Pump Contactor, Replace. Perform only the procedures necessary to complete the repairs.

1.

2.

3.

4.

5.

6.

7.

DISPLAY KEY SWITCH BRACKET CONTROLLER PUMP CONTACTOR HORN BATTERY DISCONNECT SWITCH AND MAIN CONTACTOR 8. CHARGER CONVENIENCE PORT 9. CHARGER Figure 3. Controller Panel Assembly

6

The contactor tips are made of special silver alloy.

The contacts will look black and rough from normal operation. This condition does not cause problems with the operation of the lift truck. Cleaning is not necessary. DO NOT USE A FILE ON THE CONTACTS. DO NOT LUBRICATE THE CONTACTS. Replace contacts when the silver alloy is worn away to the base support metal.

2200 SRM 1508

Repairs

Remove Refer to Figure 4 for the following procedures.

1. Remove contactor as described in Pump Contactor, Replace.

2. Remove screws (4) that fasten the top cover to the coil and frame.

3. Remove cover, moving contact (2), and return spring.

4. Remove capscrews, washers, and nuts that make up the fixed contactor tips (1) from the top cover.

5. If a coil will be replaced, remove coil frame and remove end cap from frame.

6. Remove coil from frame.

Install 1. Install new coil on frame and install end cap.

2. Install moving contact (2) and return spring.

3. Install capscrews, washers, and nuts that make up the fixed contactor tips (1) to the top cover.

NOTE: Check that the moving contactor and springs move freely without binding.

4. Install cover to coil and frame using screws (4).

5. Install contactor assemblies on the lift truck as described in Pump Contactor, Replace.

1.

2.

3.

4.

5.

6.

7.

FIXED CONTACTS MOVING CONTACTS TOP COVER SCREW RETURN SPRING COIL AND FRAME END CAP Figure 4. Contactor

7

Fuses

2200 SRM 1508

Fuses WARNING The capacitor in the transistor controller can hold an electrical charge after the battery is disconnected. To prevent electrical shock and personal injury, discharge the capacitor before inspecting or repairing any component in the drive unit compartment. Wear safety glasses. Make certain the battery has been disconnected.

The motorized hand trucks use a single 4-amp (FU2) fuse for the control circuit, and 175-amp (FU1) fuses for both the drive motor and the hydraulic pump motor. The fuses are located on the contactor panel. Remove and replace as required.

See Figure 5 and Figure 6.

If it cannot be determined visually that a fuse has failed, check for continuity using an ohmmeter. To replace FU1, loosen nuts retaining it. Install a new fuse and tighten nuts. FU2 is retained by a fuse holder. Make certain that any replacement fuse is of the right amperage before installation.

1. FU2 FUSE

2. FU1 FUSE

Figure 5. Control Circuit Fuse

8

2200 SRM 1508

Fuses Legend for Figure 6 1. BATTERY DISCONNECT SWITCH AND MAIN CONTACTOR 2. NUT 3. WASHER 4. FU1 FUSE

Figure 6. Electrical Components

9

Battery Disconnect Switch/Main Contactor and Coil

2200 SRM 1508

Battery Disconnect Switch/Main Contactor and Coil DISCONNECT SWITCH, CHECK

2. Install the two screws used to retain the switch.

1. Turn the key switch to the OFF position and ensure Disconnect Switch is pushed into down position.

3. Install all wires and cables removed from the switch.

2. Disconnect terminals from Disconnect Switch.

3. When the Disconnect Switch button is DOWN, there should be no continuity between disconnect switch terminals. When the Disconnect Switch is in the UP position there shall be continuity between terminals.

4. Install the drive unit compartment cover.

5. Turn the key switch to the ON position and connect the battery.

6. Test the switch for proper operation.

MAIN CONTACTOR COIL, CHECK

DISCONNECT SWITCH REMOVE

NOTE: The contactor contains no serviceable parts and must be replaced as a complete assembly.

1. Turn the key switch to the OFF position and disconnect the battery.

1. Disconnect coil wires.

2. Remove the drive unit compartment cover. See AC Motor Repair 0620SRM1513, Accessing the Drive Unit Compartment.

3. Tag and remove all cables and wires attached to the switch.

4. Remove the two screws retaining the switch to the lift truck frame. See Figure 6.

5. Remove the switch.

DISCONNECT SWITCH INSTALL 1. Install the switch into the opening on the lift truck frame.

10

2. Test contactor coil using an ohmmeter to measure the resistance. The coil should read 30 ohms, ±5%.

3. Remove and replace contactor if resistance readings indicate a short circuit in both directions or if there is an open circuit in both directions. Make sure coil wires are connected to the proper terminals.

2200 SRM 1508

Horn

Horn REMOVE

INSTALL

1. Turn the key switch to the OFF position and disconnect the battery.

1. Position the horn on the two studs on the contactor bracket.

2. Remove drive unit compartment cover. Refer to AC Motor Repair 0620SRM1513, Accessing the Drive Unit Compartment.

2. Install the lock nuts on the studs.

3. Tag and remove the wires attached to the horn.

4. Install the drive unit compartment cover.

4. Remove the two lock nuts retaining the horn to the contactor bracket. See Figure 3.

5. Turn the key switch to the ON position and connect the battery.

5. Remove the horn from the lift truck.

6. Operate the horn to confirm proper operation.

3. Install all wires removed from the horn.

Brake and Interlock Sensor REMOVE 1. Position the lift truck on a level surface. Turn the key switch to the OFF position and disconnect the battery.

2. Remove the drive unit compartment cover. Refer to AC Motor Repair 0620SRM1513, Accessing the Drive Unit Compartment.

3. Disconnect the sensor lead connector from the truck harness.

4. Lower the tiller handle and remove the nut retaining the sensor to the tiller handle. See Figure 7.

11

Brake and Interlock Sensor

2200 SRM 1508 4. Reconnect the sensor lead to the truck harness.

CHECK 1. Turn the key switch to the ON position.

2. Move the tiller handle down and check that the brake releases when the handle is in the operating position. See Figure 8.

1. TILLER HANDLE 3. NUT 2. SENSOR Figure 7. Brake Sensor 5. Remove the sensor.

INSTALL 1. Install the sensor onto the tiller handle.

2. Adjust the sensor so the end of the sensor is no more than 4 mm (.16 in.) from the tiller handle bracket.

3. Tighten the nuts retaining the sensor to the tiller bracket.

12

1. BRAKE ON 2. BRAKE OFF

3. BRAKE ON

Figure 8. Brake Operation 3. Continue moving the handle down and check that the brake engages when the handle is fully lowered.

4. Adjust the sensor if necessary.

5. Install the drive unit compartment cover.

2200 SRM 1508

Steer Reduction Sensor

Steer Reduction Sensor REMOVE NOTE: Note routing of steer reduction sensor wiring prior to removal to help during installation.

1. Position lift truck on flat level surface. Turn key switch to OFF position and disconnect battery.

2. Remove drive unit compartment cover. Refer to AC Motor Repair 0620SRM1513, Accessing the Drive Unit Compartment .

3. Loosen upper and lower locknut 1-2 turns and slide sensor out of mounting bracket. See Figure 9.

4. Disconnect sensor from main wiring harness connector located under pump connector. See Figure 9.

5. Remove sensor from lift truck.

Legend for Figure 9 1.

2.

3.

4.

5.

6.

LOCKNUT STEER REDUCTION SENSOR MOUNTING BRACKET MAIN WIRING HARNESS CONNECTOR PUMP CONTACTOR BUTTON HEAD CLAMP

INSTALL 1. Route steer reduction sensor around MDU and AC Motor as noted during removal.

2. Connect sensor to main wiring harness connector located under pump contactor. See Figure 9.

3. Slide sensor into mounting bracket and tighten upper and lower lock nuts. See Figure 9.

4. Using two button head clamps, secure sensor wiring to mounting bracket. See Figure 9.

5. Install drive unit compartment cover, refer to AC Motor Repair 0620SRM1513, Accessing the Drive Unit Compartment .

Figure 9. Steer Reduction Sensor

13

Height Limit

2200 SRM 1508

Height Limit Height limiting is controlled by the height limit switch in the controller. When the controller senses a high current draw from the hydraulic pump, it will shut down the pump. There are two separate incidents that will cause this current draw: The

first is when the lift cylinder reaches maximum height, and the second is when the load exceeds the rated capacity. In either case, the controller will shut down the pump.

Control Handle DISASSEMBLE WARNING DO NOT make repairs or adjustments unless you have been properly trained and authorized to do so. Improper repairs and adjustments can create dangerous operating conditions. DO NOT operate a lift truck that needs repairs. Report the need for repairs to your supervisor immediately. If repair is necessary, attach a DO NOT OPERATE tag to the control handle and disconnect the battery.

NOTE: It is not always necessary to remove and disassemble all the components that make up the control section of the steering handle to replace a damaged part. Perform only the steps necessary to replace the damaged parts. See Figure 13.

1. Move the lift truck to a safe, level area and block the drive wheel to prevent movement of the lift truck.

2. Turn the key switch to the OFF position and disconnect the battery.

3. The handle is comprised of two molded-plastic halves and is held together by capscrews. Remove the screws.

4. Disengage the hooks under the auto-reverse switch. Slide the upper half off of the lower half using a gentle rocking motion while lifting and pulling the upper half away from lower half.

5. Unplug the handle wiring harness from the control handle card.

14

6. Place upper half of the handle upside down on a secure, level work surface so the internal parts are facing up.

NOTE: Make note of the position of the butterfly knobs relative to the handle BEFORE removal.

7. Remove one of the butterfly knobs by removing the screw that holds it to the handle.

8. Using the remaining butterfly knob, slide the shaft out of the handle. Be careful not to rotate the shaft within the control handle card.

9. Refer to the wiring diagram, or draw a sketch of where each of the push button switches are plugged into the control handle card. Unplug switches from the control handle card and remove the card.

CONTROL HANDLE CARD NOTE: Control handle cards will be blue in color and should be used as replacement cards regardless of color of the card removed.

NOTE: Verify that the magnetic holder of the thumbwheel switch has been installed in the proper position. See Figure 10.

After servicing the control handle head, it may be necessary to configure and/or calibrate the control handle card.

Configure Refer to Figure 10 for the following instructions.

2200 SRM 1508

Control Handle

1. JUMPER TERMINALS (SV2) 2. HORN SWITCH (S1) 3. THUMBWHEEL SWITCH (MAGNETIC HOLDER)

4. LED DISPLAY SCREEN 5. BELLY SWITCH (S) 6. TURTLE SWITCH (S2)

Figure 10. Control Handle Card 1. Partially assemble the control handle head. Refer to Figure 13.

2. Connect the control handle card wiring, verify that the battery is connected, and turn the key switch to the ON position.

3. The LED will display the program setting for approximately five seconds. See Figure 10. The proper control handle card setting for this model is 7. If the correct number is displayed on the LED, the control handle card is configured correctly.

4. To begin configuring the card, turn the key switch to the OFF position.

5. Move the jumper from P (park) to C (configure).

See Figure 11.

1.

2.

3.

4.

5.

P (PARK/HOME POSITION D (NOT USED) T (TEACH/CALIBRATE) C (CONFIGURE) JUMPER TERMINAL (SV2) Figure 11. Jumper Terminal (SV2)

15

Control Handle 6. Turn the key switch to the ON position and view the LED display.

NOTE: For truck model W45ZHD (A419), the configuration value shall be set until the seven segment display reflects letter C.

2200 SRM 1508 3. Verify that the battery is connected and turn the key switch to the ON position. The LED will display a symbol (see Figure 12 view A or B) to signal that the card is in calibration mode. a. If LED displays as shown in Figure 12 view A, return butterfly to neutral then press left lift button. The LED will display as shown in Figure 12 view B.

7. Press and release the S2 (turtle) switch or S3 (horn) switch to change the number displayed on the LED to the correct value.

8. Press and release the S (belly) switch to save the value. A decimal will appear on the LED display beside the number showing it has been saved.

9. Turn the key switch to the OFF position and move the jumper to the park (P) position.

10. Turn the key to the ON position and view the LED to verify the correct number has been saved. The LED will display the program setting for approximately five seconds.

Calibrate Refer to Figure 10 for the following instructions.

1. Verify that the key switch is in the OFF position.

2. Move the jumper from P (park) to T (teach). See Figure 11. a. Ensure the leads from the Right Lift switch connects to the JP10 socket and the leads from the Right Lower switch connects to the JP12 socket. See Figure 10. b. Ensure the leads from the Left Lift switch connects to the JP14 socket and the leads from the Left Lower switch connects to the JP15 socket. See Figure 10. c. Ensure the tiller harness connects to AJ2 socket. See Figure 10.

16

A. B. C. D. E.

CALIBRATION MODE CALIBRATION MODE ROTATION RIGHT SEGMENT COMPLETE ROTATION LEFT SEGMENT COMPLETE ALL SEGMENTS COMPLETE AND SAVED Figure 12. LED Views

2200 SRM 1508 NOTE: "Rotation Right" direction is specified by label printed on face of card.

4. Rotate the thumbwheel in the "Rotation Right" direction (toward the forks) and hold to the mechanical stop. Press the left side lift button.

5. The LED screen will change to show this segment complete. See Figure 12, view C. Release the thumbwheel so it returns to the neutral position.

NOTE: "Rotation Left" direction is specified by label printed on face of card.

6. Rotate the thumbwheel in the "Rotation Left" direction (toward the operator) and hold to the mechanical stop. Press the left side lower button.

Control Handle

ASSEMBLE 1. Install control handle card in the upper half of control handle. See Figure 13.

NOTE: When inserting knobs, make sure that flange on one of the butterfly knobs inserts between spring on handle.

2. Slide shaft and butterfly knob into control handle card. Be careful not to rotate the shaft inside the control handle card.

3. Connect the switches and wire harness connectors.

4. Plug handle wiring harness into control handle card.

CAUTION

7. The LED screen will change to show this segment complete. See Figure 12, view D. Release the thumbwheel so it returns to the neutral position.

DO NOT force the upper half onto the lower half as this will cause damage to the retaining hooks of the upper half.

8. Move the jumper from T (teach) to P (park). See Figure 11.

5. To install upper half of handle onto the lower half:

9. The LED screen will change to show a decimal beside the completed segments indicating they have been saved. See Figure 12, view E.

a. Tip the upper half up and align the hooks under the auto-reverse switch. b. Lower the upper half onto the lower half.

10. Use diagnostic from handset to verify the “Throttle” output 95% and above for both directions.

6. Install capscrews to retain upper half of control handle to lower half.

11. Recycle the key switch OFF and ON and test all truck functions for proper operation.

7. Connect battery cable the test control handle operation.

17

Control Handle

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

CAPSCREW WASHER RH BUTTERFLY KNOB BUSHING BELLY SWITCH COVER LOCKING LEVER SPRING CAPSCREW TILLER HEAD (LOWER HALF) CAPSCREW SPRING PUSH BUTTON (REAR COVER) SCREW

2200 SRM 1508

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

SUPPORT CONTROL HANDLE CARD SHAFT LH BUTTERFLY KNOB SPRING TILLER HEAD (UPPER HALF) LABEL PUSH BUTTON ASSEMBLY LABEL SPRING HORN BUTTON SPRING

Figure 13. Control Handle

18

2200 SRM 1508

Charger and Convenience Port

Charger and Convenience Port REMOVE 1. Position lift truck on level surface. Turn key switch to OFF position and disconnect the battery.

2. Remove drive unit compartment cover. Refer to AC Motor Repair 0620SRM1513, Accessing the Drive Unit Compartment .

3. Reach up between control panel and charger convenience port and unscrew lock nut holding convenience port to control panel. See Figure 14.

4. Unplug power cord for charger convenience port from bottom of charger and unplug connector for convenience port LED. See Figure 14.

CAUTION When removing convenience port and power cord, use care not to damage convenience port, power cord, or LED connector as you feed them through the front of the control panel.

5. Remove convenience port from front of control panel. See Figure 14.

1.

2.

3.

4.

5.

6.

CHARGER CONVENIENCE PORT LOCKNUT CONTROL PANEL POWER CORD CONNECTOR ANTI-ROTATION PIN Figure 14. Charger Convenience Port

19

Charger and Convenience Port 6. Disconnect two electrical connectors from main wiring harness. See Figure 15.

7. Remove electrical wire from B- terminal on controller. See Figure 15.

8. Remove two nuts holding charger to control panel. See Figure 15.

9. Pull charger away from control panel and out of lift truck. See Figure 15.

2200 SRM 1508

INSTALL 1. Install charger onto control panel. See Figure 15.

2. Install two nuts holding charger onto control panel. See Figure 15.

3. Install electrical wire onto B- terminal of controller. See Figure 15.

4. Connect two electrical connectors to main wiring harness. See Figure 15.

5. Feed power cord and LED connector through front of control panel.

NOTE: When installing convenience port, make sure to align anti-rotation pins with holes in control panel.

6. Install convenience port into control panel. See Figure 14.

7. Feed power cord through lock nut prior to plugging into bottom of controller.

8. Install locknut onto convenience port and control panel. Make lock nut finger tight. See Figure 14.

9. Install drive unit compartment cover. Refer to AC Motor Repair 0620SRM1513, Accessing the Drive Unit Compartment .

1.

2.

3.

4.

5.

20

ELECTRICAL CONNECTOR ELECTRICAL WIRE NUT CHARGER CONTROL PANEL Figure 15. Charger

2200 SRM 1508

BDI Display

BDI Display REMOVE

Legend for Figure 16

NOTE: Access electrical connector and nuts through u-shaped cutout in top of control panel.

1. Disconnect electrical connector from back of BDI gauge. See Figure 16.

NOTE: Due to limited access, it is recommended that a box end wrench is used to perform this repair.

2. Remove two nuts from back of BDI gauge. See Figure 16.

3. Remove BDI gauge from front of control panel.

See Figure 16.

1.

2.

3.

4.

5.

DBI GAUGE ELECTRICAL CONNECTOR NUT CONTROL PANEL CONTROL PANEL CUTOUT

INSTALL 1. Install BDI gauge into front of control panel.

See Figure 16.

2. Install two nuts onto back of BDI gauge. See Figure 16.

3. Install electrical connector into back of BDI gauge. See Figure 16.

Figure 16. BDI Display

21

ACCUSENSE Battery Charger

2200 SRM 1508

ACCUSENSE Battery Charger CHARGER MODE/BATTERY TYPE SELECTION WARNING DO NOT use batteries types that are not approved for the charger or improper mode settings. Damage to the batteries or charger may occur if the mode setting is not correct for the type of batteries being used. If the battery manufacturer of the battery you are using is not listed, contact Service Engineering through the Contact Management System.

NOTE: Mode settings can be checked by connecting the battery charger to a 120V AC power source and watching the LED display. The LED display will flash once if the mode is set to Mode 1, twice if set to Mode 2, three times if set to Mode 3, and so forth. If the LEDs do not flash when initially connected to power, refer to Troubleshooting in this section.

NOTE: If the battery manufacturer of the battery you are using is not listed, contact Service Engineering through the Contact Management System.

The battery charger has 16 mode settings. The proper mode setting is determined by the type batteries being used in the battery pack. Note that batteries must be uniform in brand and model. Do not mix differing battery sizes, construction types, or old batteries with new batteries. See Figure 18.

22

For lift trucks manufactured after May, 2013, the mode key has been replaced with a dim switch. Removing the Charging Mode Label voids warranty.

Contact Service Engineering to set charging mode for replacement batteries, see Figure 17.

1. USB PORT (FACTORY USE ONLY) 2. MODE PORT DIM SWITCHES Figure 17. Mode Port

2200 SRM 1508

ACCUSENSE Battery Charger

Figure 18. Switch Position Mode Chart

23

ACCUSENSE Battery Charger

2200 SRM 1508

Changing Mode Setting NOTE: Mode settings can be checked by connecting the battery charger to a 120V AC power source and watching the LED display. The LED display will flash once if the mode is set to Mode 1, twice if set to Mode 2, three times if set to Mode 3, and so forth. If the LEDs do not flash when initially connected to power, refer to Troubleshooting in this section.

Modes are set by the sequence of the dim switches.

Tampering with the Charging Mode Label voids warranty, contact Service Engineering for dim switch settings.

CONVENIENCE PORT General This charger is connected to a convenience port which is located in the dash board of the truck. The convenience port has an LED status lights that display in the same manner as the charger. The con-

venience port will be connected to the charger via two connectors. One connector will connect the charger to the AC Input, while the other connector is for serial communication and transmission of the LED status lights.

The convenience port LED status lights display diagnostic codes according to Table 8. It also flashes from the center LED to periphery in repeating pattern if communication is lost or if the battery’s voltage is below charger’s minimum voltage for charging threshold. Verify the connection from the 4 pin connector from convenience port to the 4 socket connector from charger. If flashing code continues, use an alternate charger to increase battery voltage reading to a voltage sufficient for the charger to continue charging.

Use schematic below to connect charger. For the interlock circuit, charger 2-conductor lead CPP 01-B connects to main harness CRS 01-A. Note: CPP 01B has been identify in harness for reference only, but may not be labeled physically in charger lead.

Figure 19. Battery Charger Diagram

24

2200 SRM 1508

ACCUSENSE Battery Charger Legend for Figure 20 1.

2.

3.

4.

RED LED: AC POWER / ERROR #1 RED LED: SHUTDOWN / ERROR #2 RED LED: BATTERY DETECTION / ERROR #3 YELLOW LED: FLASH WHEN TESTING / CONTINUOUS WHEN CHARGING / ERROR #4 5. GREEN LED: ON WHEN CHARGED

LED Status Display The charger has five colored LEDs located on the top of the charger. The LEDs are used to indicate the status of the charger during operation. The order of the LEDs may vary with models, but are labeled to identify their function. See .

Figure 20. LED Display INDICATOR

PORT

COLOR

FUNCTION

Power ON

PWR

RED

Illuminates continuously when AC power is present.

Abnormal Shutdown

SDN

RED

Flashes if abnormal shutdown has occurred.

Detection Error

DET

RED

Illuminates continuously when battery is not connected to charger or battery voltage is less than 2V.

Charging

CHG

YELLOW

Charge status indicator - flashes during charging cycle

Charged

CHD

GREEN

Illuminates continuously when battery is fully charged.

Charging

CAUTION The charger comes factory set to the battery installed at the factory and must be changed if using different batteries. Using an improper charger mode for your battery pack may cause severe damage to batteries or charger. Refer to Charger Mode/Battery Type Selection in this section to verify the proper mode setting for your battery pack.

Following the start-up flashing of the LEDs, the red, POWER ON, LED will illuminate to indicate AC power is applied to the charger and will begin the charging cycle.

The charger uses a 5-Step charging process: 1. Pre-Qualification Test.

During this step, the yellow, CHARGING, LED will flash on and off every two seconds.

The charger is checking for faults prior to the

start of charging. Depending on the condition and state of charge of the batteries, this step can take from 45 seconds up to 5 hours.

2. Regulating Current.

During this step, the charger will be regulating current to the batteries and will be operating at full rated output. The yellow, CHARGING, LED will be constantly illuminated during this step.

3. Regulating Voltage During this step, the charger will be regulating voltage to the batteries. The yellow, CHARGING, LED will remain illuminated.

When the batteries have reached 80 to 90 percent of full charge, the yellow, CHARGING, and the green, CHARGED, LEDs will be illuminated.

4. Charge Complete.

During this step, the green, CHARGED, LED will remain illuminated. AC power can now be disconnected from the charger.

5. Recycle Stage.

25

ACCUSENSE Battery Charger If the charger remains connected to power for 28 days, a completely new charge cycle will begin to keep batteries fully charged during long periods of not being used.

NOTE: If the charger noted an abnormal charge condition during the charging, the charger will attempt to shutdown and will flash one or all three of the red LEDs on the top of the charger. If this condition occurs, see Troubleshooting in this section.

Operating temperature range for the charger is -10 to 55°C (14 to 131°F). If charger is below or above indicated temperatures, locate the truck to an area where charger can return to the operating temperature range.

TROUBLESHOOTING

2200 SRM 1508 2. Check that the charger is configured for the proper battery mode/type: a. What is the proper charger mode for the type batteries being used?

(1)

Refer to Charger Mode/Battery Type Selection.

b. What mode is the charger currently set on?

(1)

Connect the charger plug to a 120 volt AC power source using a 20 amp rated extension cord.

(2)

How many times do all 5 LEDs flash upon connection?

c. Is the charger currently set to the proper mode for the battery type being used?

General

(1)

YES: Proceed to Step 3.

NOTE: The charger runs a pre-qualifying test (yellow charging light flashing) at the beginning of the charge cycle to determine the condition of the battery. This test may last from 45 minutes to five hours. After the test is complete, the charger should begin charging (yellow charging light continuous) or may display an Error Mode by flashing one or more of the red LEDs. If an Error Mode is displayed, stop the general troubleshooting and follow the chart and procedures in Error Modes in this section.

(2)

NO: Change the charger mode to the proper setting for the battery type being used. See or Changing Mode Setting . After changing the mode setting repeat Step b to verify the proper mode has been selected.

1. Check AC power supply to charger: a. Connect the charger plug to a 120 volt AC power source using a 20 amp rated extension cord. b. Do all 5 LEDs simultaneously flash at least once upon connection? (LEDs should flash between one to four times depending on battery type/mode configuration.)

26

(1)

YES: Proceed to Step 2.

(2)

NO: Check AC power supply to charger: Inspect all cabling for proper connections (check for loose or corroded connectors) or broken wires. Repair as necessary and repeat Step 1. If LEDs still do not flash at least once upon connecting power, replace the charger.

NOTE: The charger runs a pre-qualifying test (yellow charging light flashing) at the beginning of the charge cycle to determine the condition of the battery. This test may last from 45 minutes to five hours. After the test is complete, the charger should begin charging (yellow charging light continuous) or may display an Error Mode by flashing one or more of the red LEDs. If an Error Mode is displayed, stop the general troubleshooting and follow the chart and procedures in Error Modes in this section.

3. Is the Power On LED illuminated continuously when the charger is connected to a 120 volt AC power source? a. YES: Proceed to Step 4. b. NO: Replace the charger.

4. Is the Detection LED illuminated continuously when the charger is connected to a 120 volt AC power source?

2200 SRM 1508

ACCUSENSE Battery Charger

a. YES: Battery is not connected to charger or battery voltage is less than 2V. Check connections. If connections are clean and tight, troubleshoot the battery pack. See Battery Pack Troubleshooting. b. NO: Proceed to Step 5.

a. Connect the voltmeter to the charger's positive (Red) and negative (Black) connections at the battery terminals. Record the voltage and then monitor it for approximately 3 minutes. Did the voltage INCREASE while monitoring?

(2)

NO: Replace the charger.

a. YES: Proceed to Battery Pack Troubleshooting. b. NO: It is recommended that all batteries in the battery pack be replaced.

a. YES: Proceed to Step 6.

6. Check the output of the charger using a digital voltmeter:

YES: The charger is functioning correctly. Proceed to Step 7.

7. Was the voltage reading in Step 6 higher than 16VDC?

5. Is the Charging LED either flashing or illuminated continuously when the charger is connected to a 120 volt AC power source?

b. NO: If no other LEDs are flashing, replace charger.

(1)

Error Modes The three red LEDs are used to troubleshoot the charger. Observe the operation of the Power On, Abnormal Shutdown, and the Detection Error LEDs to determine the cause for the error notification. See Table 2.

Table 2. LED Error Codes CONDITION

LED 1

LED 2

LED 3

LED 4

LED 5

Battery Voltage High

Off

Off

Off

Off

Flash

Battery Polarity Reversed

Off

Off

Off

Flash

Off

Output Overload

Off

Off

Off

Flash

Flash

Battery Pack Unbalanced - 1

Off

Off

Flash

Off

Off

Battery Pack Unbalanced - 2

Off

Off

Flash

Off

Flash

Excessive Charging Time - 1

Off

Off

Flash

Flash

Off

Excessive Charging Time - 2

Off

Off

Flash

Flash

Flash

Excessive Overload

Off

Flash

Off

Off

Off

Battery Testing - 1

Off

Flash

Off

Off

Flash

Battery Testing - 2

Off

Flash

Off

Flash

Off

Inhibit Control Defective

Off

Flash

Off

Flash

Flash

Internal Over Temperature - 1

Off

Flash

Flash

Off

Flash

27

ACCUSENSE Battery Charger Battery Voltage High indicates the charger is sensing it is connected to a battery pack with a voltage rating greater than 24 volts. Verify the battery pack is the correct voltage.

Battery Polarity Reversed indicates an incorrect connection of the battery charger to the battery pack. Verify charger connections.

Output Overload indicates the charger sensed a high current draw during the charging cycle. Verify there is no load on the batteries during charging.

Charge Level Unbalanced indicates some batteries are at a much higher state of charge than other batteries in the battery pack. Check the condition of each battery.

Excessive Charging Time error occurs when the preset maximum charge time has been exceeded.

Verify there is no load on the battery pack during charging. Verify all batteries are in good condition and will accept a charge.

Excessive Overload error occurs if a heavy load is placed on the battery pack during charging and the charger senses a decreasing battery voltage. Remove external load.

Excessive Discharged error occurs when a battery pack will not reach 21 volts within five hours of charging.

Battery Testing error occurs when a battery don’t charge to its fullest within 3 hours because either was extremely discharged or it had an external load connected to the battery.

Internal Over Temperature (1 and 2) error occurs when charger went above internal maximum temperature limits. Check cooling fan for obstruction.

28

2200 SRM 1508

A.C. Convenience Port Accessory (Optional) If the optional A.C. Convenience Port Accessory is include with your system, the L.E.D. display mirrors the Charger L.E.D. Display – with one exception: If an L.E.D. pattern flashes from the center L.E.D. out, in a repeating pattern, the Port is annunciating a Lost Communications error. Check wiring for continuity.

Battery Pack Troubleshooting

WARNING Disconnect the charger from the AC power source before proceeding.

Always wear protective gear including eye protection and suitable gloves when servicing battery packs.

NOTE: For general information about battery maintenance and procedures, refer to Industrial Battery 2240SRM0001.

1. Measure the specific gravity (SG) level for each battery cell (after a charging cycle).

After a charging cycle, the SG measurement for each cell should be 1.265 or greater.

From cell to cell within one battery: The SG measurements should not vary more than 0.020. If variance is greater than 0.020, it is recommended that the battery be replaced with the same type of battery as the other three batteries in that pack.

2200 SRM 1508

ACCUSENSE Battery Charger

From battery to battery within one battery pack: The SG measurements should not vary more than 0.050. If one of the batteries has an SG reading 0.050 below the other three batteries and the voltage is less than 6.3VDC after allowing the batteries to set four hours without any load, it is recommended that the battery with lowest SG be replaced with the same type of battery as the other 3 batteries in that pack.

3. Battery Replacement: Each battery manufacturer has a specific "charge set-up" that will give your truck the best battery life and drive time for your truck. If the "charge set-up" is not correct, you can damage the batteries and will not get the full performance you expect. Make sure that the battery charger is set to the proper charging mode for your battery pack.

WARNING

•

DO NOT mix manufacturers or battery types in the power pack

•

It is not recommended to change out batteries independently. All batteries should be changed together when battery pack is updated.

DO NOT overfill battery cells.

2. Verify water level in each cell of each battery: •

Before Charging: Only add minimal amount of distilled water to cover top of plates if needed.

•

After Charging: Add distilled water as needed to fill to the bottom of cell opening.

Table 3. Troubleshooting

PROBLEM

Lift truck will not move

Mast will not raise the forks

Operator controls do not work

POSSIBLE CAUSE

PROCEDURE OR ACTION

Dead battery

Recharge or replace battery

Failed (Open) fuse

Replace Failed (Open) fuse

Brake is applied

Test the brake to ensure wiring to brake is good

Drive motor not operating

Repair or replace drive motor

Sequencing fault

Return handle to rest and recycle

Dead battery

Recharge or replace battery

Failed (Open) fuse

Replace Failed (Open) fuse

Lift pump motor wiring loose or dis- Reconnect or tighten loose wiring connections connected Lift pump motor not operating

Repair or replace lift pump motor

Dead battery

Recharge or replace battery

Failed (Open) fuse

Replace Failed (Open) fuse

Control handle wiring loose or disconnected

Check wiring and tighten or connect as needed

An individual switch is damaged

Check switch and replace if inoperative

29

NOTES

30

TECHNICAL PUBLICATIONS 2200 SRM 1508

12/14 (4/14)(12/13)(6/11)

FRAME W45ZHD [A419]

PART NO. 4099864

0100 SRM 1665

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR •

• • • • • • • • • • • • • •

The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the product. Updated technical service information may be available from your local authorized Hyster® dealer. Service Manuals provide general guidelines for maintenance and service and are intended for use by trained and experienced technicians. Failure to properly maintain equipment or to follow instructions contained in the Service Manual could result in damage to the products, personal injury, property damage or death.

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 when making 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.

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury and property damage.

On the lift truck, the WARNING symbol and word are on orange background. The CAUTION symbol and word are on yellow background.

Frame

Table of Contents

TABLE OF CONTENTS General .....................................................................................................................................................................1 Frame Separation and Assembly ........................................................................................................................... 2 Frame Separation ............................................................................................................................................... 2 Frame Assembly ..................................................................................................................................................2 Painting Instructions .............................................................................................................................................. 2 Label Replacement .................................................................................................................................................. 3 This section is for the following models: (W45ZHD) [A419]

©2013 HYSTER COMPANY

i

"THE QUALITY KEEPERS" HYSTER APPROVED PARTS

0100 SRM 1665

General

General This section contains the description and repair procedures for the frame weldments of the lift truck. This model has integral mounting brackets and holes factory drilled for the mounting of covers, the lift pump and motor, electrical components, lifting mechanisms, and the master drive unit (MDU). See Figure 1 . The fork frame weldment is linked to the main frame weldment by the lift links

of the lifting mechanism system. The lift cylinder actuates to evenly lift the fork frame and raise the load. The battery end of the fork frame weldment is lifted directly by the cylinder and pivots on the lift links to the main frame weldment. The fork tips are lifted simultaneously by push rods connecting the lift links to the load wheel linkages near the end of the forks.

1. FRAME 2. CASTING

3. COVER Figure 1. Frame Weldment

1

Frame Separation and Assembly

0100 SRM 1665

Frame Separation and Assembly FRAME SEPARATION In some cases a fork frame or a drive unit frame may be damaged, while the rest of the truck is still usable. The two frames may be separated from each other by using the following steps.

1. Raise the motorized lift truck to its maximum height. Move the key to the OFF position. Disconnect the battery.

2. Remove the drive unit compartment covers. See Accessing the Drive Unit Compartment (A290) (A249) in AC Motor Repair 0620SRM1513 .

3. Position blocks under both sides of the truck in the area of the battery compartment and under both forks. See How to Put a Lift Truck on Blocks in Periodic Maintenance 8000 SRM/YRM 1665.

4. Remove the pin retaining the hydraulic cylinder to the frame. See Hydraulic Cylinder in Hydraulic System 1900SRM1506.

5. Manually retract the lift cylinder while holding the lower switch on.

6. Remove the battery. See How to Change the Battery in Periodic Maintenance 8000 SRM/YRM 1665.

7. Remove the drive unit frame pivot pins retaining the rocker arm to the drive unit frame. See Rocker Arm and Pull Rods, Remove in Lifting Mechanism 4000SRM1509.

8. Carefully move one of the frames away from the other.

FRAME ASSEMBLY 1. Align both frames so the pins may be installed to assemble the frames to each other.

2. Install both drive unit frame pivot pins to attach the rocker arms to the drive unit frame.

See Rocker Arm and Pull Rods, Install in Lifting Mechanism 4000SRM1509.

3. Install the retainer pin to attach the hydraulic cylinder to the fork frame. See Hydraulic Cylinder, Install in Hydraulic System 1900SRM1506.

4. Install the battery. Refer to How to Change the Battery in Periodic Maintenance 8000 SRM/YRM 1665.

5. Install the drive unit compartment cover.

6. Remove the blocks and lower the motorized lift truck to the floor.

7. Test the operation of the truck before returning the truck to service.

Painting Instructions WARNING Always use solvents and paints in an area with ventilation. DO NOT use solvents or paints near heat or fire.

Cleaning solvents can be flammable and toxic and can cause skin irritation. Wear protection for eyes and skin. When using cleaning solvents, always follow the recommendations of the manufacturer.

1. Remove all dirt from the surface to be painted.

Clean the area to be painted using a solvent for painted surfaces. Remove all oil and grease.

2

2. Remove the top surface of paint and all rust from the metal using sandpaper. Paint all metal surfaces where the paint is completely removed using primer. Apply the primer before applying the color paint.

3. Protect all surfaces that will not be painted.

DO NOT paint cylinder rods, cables, labels, plates, or controls.

4. Paint all the surfaces the original color, using Hyster® paint. Follow the directions on the container.

0100 SRM 1665

Label Replacement

Label Replacement Replace damaged Warning or Caution labels immediately.

1. Make sure the surface is dry and free of oil or grease. DO NOT use solvent on new paint.

Clean the surface of old paint using a cleaning solvent.

If labels or information plates are missing or damaged, they must be replaced. See Figure 2.

2. Remove the paper from the back of the label.

DO NOT touch the adhesive surface.

WARNING

NOTE: The nameplate cover is installed using rivets. Remove old rivets before installing a new nameplate cover. See your Hyster® lift truck dealer to make sure the nameplate cover information is correct and complete before installing a new nameplate cover. Fasten the nameplate cover with the rivet heads outside.

NOTE: The label cannot be moved after it touches the surface.

3. Carefully hold the label in the correct position above the surface. Put the label in the correct position on the surface. Make sure all air is removed from under the label and the corners and edges are tight. See Figure 2.

3

Label Replacement

1.

2.

3.

4.

WARRANTY LABEL NAMEPLATE E - STOP LABEL BDI LABEL

0100 SRM 1665

5. HYSTER LOGO LABEL 6. PINCH WARNING LABEL 7. WARNING LABEL Figure 2. Labels and Decals

4

TECHNICAL PUBLICATIONS 0100 SRM 1665

12/13

HYDRAULIC SYSTEM P2.0 [A290]; W45ZHD [A419]

PART NO. 4035863

1900 SRM 1506

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR •

• • • • • • • • • • • • • •

The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the product. Updated technical service information may be available from your local authorized Hyster® dealer. Service Manuals provide general guidelines for maintenance and service and are intended for use by trained and experienced technicians. Failure to properly maintain equipment or to follow instructions contained in the Service Manual could result in damage to the products, personal injury, property damage or death.

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 when making 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.

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury and property damage.

On the lift truck, the WARNING symbol and word are on orange background. The CAUTION symbol and word are on yellow background.

Table of Contents

TABLE OF CONTENTS General .....................................................................................................................................................................1 Special Precautions ................................................................................................................................................. 1 Operation ................................................................................................................................................................. 2 Lifting a Load ......................................................................................................................................................2 Lowering a Load ..................................................................................................................................................4 Hydraulic Lines ...................................................................................................................................................4 Hydraulic Oil .......................................................................................................................................................4 Clean ....................................................................................................................................................................4 Sound Level ......................................................................................................................................................... 4 Hydraulic Unit .........................................................................................................................................................5 Remove ................................................................................................................................................................ 5 Install ...................................................................................................................................................................5 Hydraulic Pump ...................................................................................................................................................... 6 Remove ................................................................................................................................................................ 6 Install ...................................................................................................................................................................6 Hydraulic Pump Reservoir ..................................................................................................................................... 9 Remove ................................................................................................................................................................ 9 Install ...................................................................................................................................................................9 Hydraulic Cylinder ................................................................................................................................................10 Remove .............................................................................................................................................................. 10 Repacking .......................................................................................................................................................... 10 Install .................................................................................................................................................................11 Relief Valve Adjustment ....................................................................................................................................... 12 Relief Valve Pressure Check ............................................................................................................................ 12 Relief Valve Adjust ........................................................................................................................................... 13 Troubleshooting .....................................................................................................................................................14 Lift Assemblies ..................................................................................................................................................14 Hydraulic Cylinders ..........................................................................................................................................14 Hydraulic Pump ................................................................................................................................................ 15 This section is for the following models: P2.0 [A290]; (W45ZHD) [A419]

©2015 HYSTER COMPANY

i

"THE QUALITY KEEPERS" HYSTER APPROVED PARTS

1900 SRM 1506

General

General The hydraulic system provides the force required to lift the loads on all motorized lift trucks.

The hydraulic system on the motorized lift truck consists of the following individual components: •

Pump Motor Assembly

•

Hydraulic Pump Assembly

•

Solenoid Lowering Valve

•

Pilot Relief Valve

•

Lift Cylinder

•

Reservoir

The hydraulic pump and motor assemblies are mechanically joined together as a compact unit, combining the reservoir, pump, and motor together as a single assembly. The pump is located inside of the hydraulic tank and coupled to the motor by an adapter plate, coupler drive, and four capscrews.

Hydraulic unit servicing is best performed by removing the unit from the truck to a clean work area.

Special Precautions WARNING The capacitor in the transistor controller can hold an electrical charge after the battery is disconnected. To prevent electrical shock and personal injury, discharge the capacitor before inspecting or repairing any component. Wear safety glasses.

Make certain the battery has been disconnected.

DO NOT use a screwdriver to discharge the traction motor controller.

WARNING To avoid personal injury and prevent electrical shock, perform the following steps before performing any troubleshooting or adjustments, and connecting or disconnecting a handset or PC.

CAUTION To avoid controller damage, always disconnect the battery. Discharge the capacitor and never put power to the controller with any power wire disconnected.

Never short any controller terminal or motor terminal to battery. Make sure to use proper procedures when servicing the controller.

1. Move the truck to a safe, level area. Turn the key switch to the OFF position and disconnect the battery.

2. Remove the drive unit compartment cover to access the drive unit compartment.

CAUTION DO NOT short across the motor controller terminals with a screwdriver or jumper wire.

3. Discharge the capacitors in the controllers by connecting a 200-ohm, 2-watt resistor across the controller's B+ and B− terminals. See Figure 1.

4. Remove the 200-ohm, 2-watt resistor before reconnecting the battery.

1

Special Precautions

1900 SRM 1506 Legend for Figure 1 1.

2.

3.

4.

5.

CONTROLLER POSITIVE CONNECTION INSULATED JUMPER WIRES 200-OHM, 2-WATT RESISTOR NEGATIVE CONNECTION

Figure 1. Discharging Controller

Operation LIFTING A LOAD To raise a load, the lift button must be depressed.

Depressing this switch will activate the pump motor. This torque is transferred to the pump from the motor through the motor shaft and shaft coupling.

Hydraulic oil is pumped through the system as the pump begins to operate. A vacuum created inside of the pump draws oil out of the reservoir through the suction line. Air which is drawn into the reservoir through the breather displaces the pumped oil, allowing it to be sent through the system. See Figure 2 and Figure 3. If the breather is clogged or blocked the ability of the system to lift a load will be greatly reduced.

2

As oil is pushed out of the pump, it passes through a one-way check valve to the lift cylinder. The check valve prevents oil from flowing back to the pump when lifting ceases, holding the lift cylinder in the raised position until lowered.

The piston will begin to lift the load when fluid pressure acting against it is high enough to overcome the weight of the load at rest on the forks/ platform.

When the piston is fully extended to the end of its stroke or if the load is too heavy, pressure will continue to build until the rated pressure needed to operate the relief valve is reached. When this occurs, the relief valve, which is normally closed, is forced back against its spring, creating a path for the fluid to flow back to the reservoir.

1900 SRM 1506

Operation

Once relief valve pressure is reached, hydraulic oil will continue to be diverted from the lift cylinder to the reservoir until the lift button is released or electrical power is interrupted.

Figure 2. Hydraulic Schematic

1.

2.

3.

4.

5.

6.

LIFT CYLINDER HYDRAULIC POWER UNIT CAPSCREW FITTING HOSE FITTING Figure 3. Hydraulic System

3

Operation

LOWERING A LOAD A load is lowered by depressing the lower button.

When the lower button is depressed, electric current is sent to the normally closed solenoid lowering valve, which causes it to change position and open a path for the trapped hydraulic oil to flow from the cylinder back to the reservoir.

HYDRAULIC LINES 1. All hydraulic lines must be thoroughly cleaned before installation.

2. When making repairs, use the least number of fittings and connections to minimize flow resistance and the possibility of leakage.

1900 SRM 1506 1. Flush the entire system when a failure is encountered to make sure all paint, metal chips, welding shot, and debris are removed.

2. Filter each change of oil to prevent the introduction of contaminants into the system.

3. Provide continuous protection from airborne contamination by keeping the breather clean and serviceable.

SOUND LEVEL Hydraulic system noise is caused by both improperly selected oil and loose or damaged system components.

•

Hydraulic oil with high or moderately high viscosities - At startup, temperatures can cause pump noises due to cavitation and also impedes the release of trapped air. Air does not have sufficient time to purge itself from the fluid while in the reservoir before recycling through the system.

•

Aerated Hydraulic Oil - Results in system noise that is similar to cavitation. Aerated oil is caused by the ingestion of air through the pipe joints of the inlet lines and high velocity discharge lines, as well as cylinder rod packing. Aeration can also be caused by oil discharging above the fluid level.

HYDRAULIC OIL The hydraulic oil in the system performs the dual function of the power transmission and lubrication.

Using the correct fluid is essential to proper system operation. Refer to Capacities and Specifications 8000SRM1511 - Hydraulic Oils, for the recommended hydraulic oil to be used.

Check the reservoir level when troubleshooting lifting problems. Low oil levels will make it appear that a problem exists with the battery or hydraulic system.

CLEAN Adhere to the following precautionary steps to ensure that the hydraulic system remains clean.

4

1900 SRM 1506

Hydraulic Unit

Hydraulic Unit REMOVE WARNING Batteries are heavy and can cause personal injury. Use care to avoid injury. DO NOT put hands, arms, feet, and/or legs between the battery and a solid object. Make sure the capacity of the crane and spreader bar is greater than the weight of the battery. The weight of the battery is normally shown on the battery case. The maximum battery weight is shown on the lift truck nameplate. The spreader bar must NOT be made of metal or it must have insulated straps.

WARNING Put blocks under each side of the truck under the drive unit frame. Position blocks on both sides of the load wheels. The blocks must prevent the lift truck from falling and causing personal injury or property damage.

WARNING The capacitor in the controller can hold an electrical charge after the battery is disconnected. To prevent electrical shock and personal injury, discharge the capacitor before inspecting or repairing any component in the drive unit compartment.

Wear safety glasses. Make certain the battery has been disconnected. Refer to Special Precautions in this manual.

CAUTION Make certain the hydraulic cylinder is fully collapsed.

1. Remove the drive unit compartment cover. Refer to AC Motor Repair 0620SRM1513, Accessing the Drive Unit Compartment.

2. Disconnect the battery. Use a spreader bar and lifting device to remove the battery. DO NOT allow the battery move from side to side. Make sure the battery cables have clearance. Refer to: •

Periodic Maintenance 8000SRM1510 for lift truck model A290

•

Periodic Maintenance 8000SRM1666 for lift truck model A419

3. Raise the drive wheel off the floor and put blocks under both sides of the drive unit frame.

Refer to: •

Periodic Maintenance 8000SRM1510 for lift truck model A290

•

Periodic Maintenance 8000SRM1666 for lift truck model A419

4. Discharge the capacitor. See Special Precautions.

5. Drain the hydraulic oil from the hydraulic unit into an appropriate container.

6. Tag and disconnect all of the electrical wires from the hydraulic unit.

7. Remove the hydraulic line from the hydraulic unit.

8. Loosen and remove the two capscrews attaching the hydraulic unit to the frame. Remove the hydraulic unit and place in a clean work area.

INSTALL 1. Align the hydraulic unit with the mounting holes in the frame and install the two capscrews. Tighten the hydraulic unit mounting capscrews to 35 N•m (26 lbf ft).

2. Install the hydraulic line to the hydraulic unit.

3. Connect all the electrical wires to the hydraulic unit.

4. Remove the blocks and lower the lift truck to the floor.

5. Remove the breather and add the recommended hydraulic oil until the oil level reaches the full level mark. Replace the breather. If too much hydraulic oil is added, the oil will leak from the breather during operation.

6. Install and connect the battery. Operate the lift truck until the hydraulic oil reaches operating temperature. Add additional oil if necessary.

Check for hydraulic oil leaks.

7. Install the drive unit compartment cover. Test the operation of the lift truck prior to returning the truck to service.

5

Hydraulic Pump

1900 SRM 1506

Hydraulic Pump REMOVE 1. Remove the hydraulic unit from the lift truck.

Refer to the Figure 4 or Figure 5 in this section.

2. Clean the reservoir and pump area to prevent contaminants from entering the hydraulic system.

3. Remove the capscrews retaining the reservoir to the hydraulic unit. Tap around the perimeter to break the seal and separate the reservoir from the motor assembly.

4. Remove the spring retaining screw from the suction tube.

5. Remove the suction tube and strainer by pulling down and out.

6. Remove the four capscrews retaining the pump to the drive motor.

7. Disassemble the pump assembly and coupling from the adapter.

INSTALL NOTE: The hydraulic unit includes four separate kits as shown in Figure 4 or Figure 5.

1. Clean and lubricate all components using clean hydraulic oil.

2. Replace all O-rings and seals within the unit.

3. Grease the coupler and coupler cavity with the motor resting with the adapter plate up. Align the pump mounting holes with the holes in the motor. Ensure that the tank is seated into the motor.

4. Install the four capscrews and tighten to 13.6 to 16.3 N•m (10 to 12 lbf ft).

6

5. Install the O-rings into the pump cavities. Apply grease to the return tubes. Insert tubes into pump cavities and O-rings. Grease the suction tube and insert into locking device with hole.

Install and tighten the spring retaining screw to secure the suction tube.

6. Remove the retainer and replace the O-ring.

Lightly grease the O-ring before installation.

7. Align the reservoir so the hose connections will be in the same position as they were prior to removal. Install the four capscrews to retain the reservoir.

8. Install the hydraulic unit. Refer to Hydraulic Unit - Install, in this manual.

9. Remove the breather and fill the reservoir with the recommended oil. See the section Capacities and Specifications 8000SRM1511, Hydraulic Oils. Add oil until the oil is up to the full mark. If too much oil is added, the oil will leak from the breather during operation. If too much oil has been added, drain the excess or use a suction device to remove some of the oil.

10. Run the pump for 5 seconds and energize the lowering valve at the same time so that oil gets through the pump body and valve at 0.0 psi.

Operate the forks up and down three or four times to remove air from the system. Operate the lift truck until the hydraulic oil reaches operating temperature. Remove the breather and check the hydraulic oil level. Add additional oil if necessary. Check for hydraulic oil leaks.

11. Install the drive unit compartment cover. Test the operation of the motorized hand truck before returning the truck to service.

1900 SRM 1506

Hydraulic Pump

Figure 4. Hydraulic Unit (A290)

7

Hydraulic Pump

1900 SRM 1506 Legend for Figure 4

1. MOTOR 2. ELECTRO-POPPET VALVE

3. HYDRAULIC SUB UNIT 4. FILLER TANK

1. MOTOR 2. ELECTRO-POPPET VALVE

3. HYDRAULIC SUB UNIT 4. FILLER TANK Figure 5. Hydraulic Unit (A419)

8

1900 SRM 1506

Hydraulic Pump

Hydraulic Pump Reservoir REMOVE The reservoir of the hydraulic pump unit can be removed without removing the complete hydraulic unit. The motor will also come loose, with one set of screws holding the reservoir to the subunit to the motor.

WARNING The capacitor in the transistor controller can hold an electrical charge after the battery is disconnected. To prevent electrical shock and personal injury, discharge the capacitor before inspecting or repairing any component in the drive unit compartment. Wear safety glasses. Make certain the battery has been disconnected. Refer to the Special Precautions section in this manual.

CAUTION Make certain the hydraulic cylinder is fully collapsed.

NOTE: The reservoir must be lowered below the suction tube before attempting to move the reservoir away from the lift truck. Remember the reservoir may contain hydraulic oil. Dispose of all used oil in accordance with local regulations.

1. Turn the key switch to the OFF position and disconnect the battery.

6. Clean the reservoir and the suction screen. Inspect the screen for damage and replace if necessary.

NOTE: The capscrews that hold the reservoir to the subunit also hold the motor to the subunit.

When the capscrews are removed, the motor will be resting on the subunit. When reinserting the capscrews, ensure that the motor is located correctly and the coupler is seated properly.

INSTALL 1. Lubricate a new O-ring using clean hydraulic oil and install into the pump body.

2. Align the reservoir in the proper position and install the four capscrews to retain the reservoir to the hydraulic unit.

3. Install the hydraulic lines to the hydraulic unit.

4. Remove the blocks and lower the lift truck to the floor.

5. Remove the breather and add the recommended hydraulic oil until it reaches the full mark. Replace the breather. If too much hydraulic oil is added, the oil will leak from the breather during operation. If too much oil has been added, drain or use a suction device to remove excess oil.

4. Disassemble and plug the hydraulic lines to the hydraulic unit.

6. Connect the battery. Run the pump for 5 seconds and energize the lowering valve at the same time so that oil gets through the pump body and valve at 0.0 psi. Operate the forks up and down three or four times to remove air from the system. Operate the lift truck until the hydraulic oil reaches operating temperature. Remove the breather and check the hydraulic oil level. Add additional oil if necessary.

Check for hydraulic oil leaks.

5. Remove the four capscrews retaining the reservoir to the hydraulic unit. Carefully remove the reservoir.

7. Install the drive unit compartment cover. Test the operation of the lift truck prior to returning the truck to service.

2. Remove the drive unit compartment cover. Refer to AC Motor Repair 0620SRM1513, Accessing the Drive Unit Compartment.

3. Discharge the capacitor. See Special Precautions.

9

Hydraulic Cylinder

1900 SRM 1506

Hydraulic Cylinder REMOVE WARNING Put blocks under each fork. Position blocks on both sides of the drive wheel. The blocks must prevent the lift truck from falling and causing personal injury or damage.

1. Raise the forks of the lift truck to maximum height.

2. Place blocks under the forks and block the drive tire.

3. Lower the forks onto the blocks.

4. Remove the drive unit compartment cover from the lift truck. See AC Motor Repair 0620SRM1513, Accessing the Drive Unit Compartment.

5. Remove the top center and main center covers, covering the hydraulic cylinder. Refer to Figure 6 for Step 6 through Step 9.

6. Open the battery tray so that the backside of the top center cover is showing.

7. Remove the capscrew securing the cover to the frame and lift the cover from its position.

8. Remove the three nuts securing the main center cover to the frame and remove the cover.

9. Remove the retainer from the lift cylinder rod.

10. Manually compress the lift cylinder while holding the lower switch.

11. Disconnect and plug the hydraulic line from the lift cylinder.

12. Remove the lift cylinder from the lift truck.

REPACKING CAUTION Lubricate the seals, packing, and O-rings with clean hydraulic oil before assembling.

CAUTION Make certain that none of the sealant gets into the cylinder. Allowing sealant to get into the hydraulic system may cause damage to the components within the hydraulic system.

1. Remove the gland nut from the lift cylinder barrel. See Figure 7.

2. Remove the piston rod assembly from the lift cylinder barrel.

3. Remove the end plug from the lift cylinder barrel.

4. Remove the O-rings, rod seal, and the wiper from the gland nut.

5. Remove the O-ring from the end plug.

1.

2.

3.

4.

5.

6.

TOP CENTER COVER CAPSCREW NUTS MAIN CENTER COVER HYDRAULIC CYLINDER RETAINER Figure 6. Hydraulic Cylinder Covers

10

6. Remove the two wear rings from the piston rod assembly.

7. Install the new O-rings onto the end plug and install the end plug into the barrel.

8. Install the new wear rings onto the piston rod assembly and insert into the barrel.

1900 SRM 1506

Hydraulic Cylinder

9. Install the new O-rings, rod seal, and wiper to the gland nut.

8. Install the top center and main center covers as removed.

10. Install the gland nut over the piston rod and into the barrel.

9. Install the drive unit compartment cover. Test the operation of the lift truck prior to returning the truck to service.

11. Tighten the gland nut to 275 N•m (203 lbf ft).

INSTALL 1. Insert the bottom of the cylinder into the lift truck frame.

2. Connect the hydraulic line from the hydraulic power unit to the lift cylinder.

3. Press the lift switch to extend the hydraulic cylinder into the hole in the fork frame.

4. Install the retainer into the lift cylinder rod.

5. Remove the blocks from the fork frame and lower the forks.

6. Remove the breather and add the recommended hydraulic oil until the oil is up to the full mark.

Replace the breather. If too much hydraulic oil is added, the oil will leak from the breather during operation. If too much oil has been added, drain the excess or use a suction device to remove some of the oil.

7. Run the pump for 5 seconds and energize the lowering valve at the same time so that oil gets through the pump body and valve at 0.0 psi.

Operate the forks up and down three or four times to remove air from the system. Operate the lift truck until the hydraulic oil reaches operating temperature. Check the hydraulic oil level. If necessary add additional oil. Check for hydraulic oil leaks.

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

WIPER SEAL GLAND O-RING SEAL O-RING SEAL RETAINER ROD SEAL BARREL O-RING SEAL END PLUG Figure 7. Hydraulic Cylinder

11

Relief Valve Adjustment

1900 SRM 1506

Relief Valve Adjustment RELIEF VALVE PRESSURE CHECK WARNING DO NOT make repairs or adjustments unless you have been properly trained and authorized to do so. Improper repairs and adjustments can create dangerous operating conditions. DO NOT operate a lift truck that needs repair. Report the problem to your supervisor immediately. If repairs are necessary, turn the key switch to the OFF position, attach a DO NOT OPERATE tag to the control handle, and disconnect the battery.

Always wear the proper protective equipment including eye protection and petroleum resistant gloves when servicing hydraulic components.

Thoroughly wash oil from exposed areas of skin as soon as possible.

Completely lower all lift components and relieve pressure before disassembling any part of the lift pump or disconnecting any hydraulic hoses.

The hydraulic oil is hot at normal operating temperatures. Be careful when draining the oil.

Never put your hands on pressurized hydraulic components. Pressurized hydraulic oil escaping through pin-hole leaks can be injected into the skin.

CAUTION DO NOT OVERFILL. Oil will leak from the breather/ filler cap if too full.

NOTE: Check the hydraulic oil level in the reservoir when oil is at room temperature. Remove breather cap and add recommended hydraulic oil to proper level, as required. See Hydraulic Pump Reservoir.

1. Operate lift truck until hydraulic oil reaches operating temperature (43 to 49°C (110 to 120°F)).

2. Lower the forks completely to relieve pressure from hydraulic circuit.

3. Turn key switch to the OFF position and disconnect the battery.

12

4. Block load wheels to prevent lift truck from moving.

5. Remove the drive unit compartment cover. Refer to AC Motor Repair 0620SRM1513, Accessing the Drive Unit Compartment.

6. Discharge the capacitor. See Special Precautions.

7. Clean any buildup of dirt from around the lift pump and motor assembly.

WARNING Hydraulic oil hoses and lines may be under pressure. Slowly loosen the hydraulic connections to ensure pressure has been relieved.

8. Disconnect the hydraulic hose at the pump.

9. Install a tee fitting and a pressure gauge of at least 24.8 MPa (3600 psi).

10. Verify the oil is at an operating temperature of 43 to 49°C (110 to 120°F).

11. Raise the forks completely and continue to hold the lift button. Read the pressure gauge while the pump is in relief. See the Table 1 for correct pressure.

NOTE: The pump will stop after a short period of time. Release the lower button then press and hold again to continue.

12. If the relief pressure is incorrect, refer to Relief Valve Adjust in this section.

13. After the proper relief pressure is obtained, lower the forks completely to relieve pressure from hydraulic circuit.

14. Turn the key switch to the OFF position and disconnect the battery.

Table 1. Relief Valve Settings Model

Relief Setting*

4500 lb

22.0 MPa (3200 psi)

* +0.6 -0.0 MPa (+87 -0 psi)@ 21°C (70°F) Oil Temperature Full Flow

1900 SRM 1506

Relief Valve Adjustment

15. Discharge the capacitor. See Special Precautions.

7. Connect the battery and turn key to the ON position.

16. Remove the pressure gauge and tee.

8. Recheck the relief pressure. See Relief Valve Pressure Check.

17. Reconnect the hydraulic hose to pump.

18. Connect the battery and turn the key switch to ON position.

19. Operate the hydraulic functions several times to purge the air from the hydraulic circuit.

9. Repeat as necessary, until the correct relief pressure is measured.

10. Perform Step 13 through Step 23 in Relief Valve Pressure Check to complete procedure.

20. Remove blocks from wheels.

21. Test the lift truck by lifting and lowering a load several times. Visually check for leaks.

CAUTION DO NOT OVERFILL RESERVOIR. Oil will leak from the breather/filler cap during operation if reservoir is over filled.

22. Check the hydraulic oil level in the reservoir.

Remove breather cap and add recommended hydraulic oil to proper level, as required. See the section Hydraulic Pump Reservoir.

23. Install the drive unit compartment cover.

RELIEF VALVE ADJUST Refer to the section Relief Valve Pressure Check to determine if adjustment is necessary.

1. Verify the key switch is in the OFF position and the battery is disconnected.

2. Remove the hydraulic reservoir. See Hydraulic Pump Reservoir.

3. Loosen the locking nut on the relief valve. See Figure 8.

4. Adjust the relief valve screw in small increments. Turn the adjustment screw clockwise to increase pressure. Turn the adjustment screw counterclockwise to decrease pressure.

5. Tighten the lock 15 N•m (11 lbf ft).

nut

and

torque

to

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

LIFT MOTOR PUMP HOUSING TUBE CLAMP INLET ADAPTER SCREEN SNAP RING ADJUSTMENT SCREW LOCK NUT RELIEF VALVE ASSEMBLY Figure 8. Relief Valve Adjust

6. Install the hydraulic reservoir as removed.

13

Troubleshooting

1900 SRM 1506

Troubleshooting LIFT ASSEMBLIES PROBLEM Forks fail to elevate.

Slow lifting speed and insufficient handling capacity.

Forks fail to lower.

POSSIBLE CAUSE

PROCEDURE OR ACTION

Faulty hydraulic equipment.

See Pumps and Hydraulic Cylinders below.

Deformed lifting components.

Disassemble and replace damaged parts.

Faulty hydraulic equipment.

See Pumps and Hydraulic Cylinders below.

Deformed lifting components.

Disassemble and replace damaged parts.

Deformed forks.

Disassemble, repair, or replace.

Deformed lifting components.

Disassemble, repair, or replace.

Bent hydraulic cylinder piston rod.

See Hydraulic Cylinders below.

HYDRAULIC CYLINDERS PROBLEM Oil leaks from cylinder gland around piston rod (An oil ring appears on the piston rod).

Oil leaks from welded portion.

14

POSSIBLE CAUSE

PROCEDURE OR ACTION

Foreign matter on packing.

Replace packing.

Score on piston rod.

Remove any foreign matter.

Smooth rod surface with an oil stone. If oil still leaks, disassemble and repack cylinder.

Scores on wiper ring lip.

Replace wiper ring.

Unusual distortion of wiper ring.

Replace wiper ring.

Chrome plating is stripped.

Replace piston rod or renew chrome plating.

Cylinder tube damaged.

Replace cylinder tube.

1900 SRM 1506

PROBLEM Rod spontaneously retracts.

Wear limit (clearance between cylinder tube and wear ring).

Troubleshooting

POSSIBLE CAUSE

PROCEDURE OR ACTION

Scores on inner surface of tube.

Smooth surface with an oil stone.

Score on tube.

Replace cylinder tube.

Score on piston ring.

Replace piston ring.

Foreign matter on packing ring.

Replace packing.

Considerable score on lip of packing ring.

Replace packing.

Unusual distortion of packing ring.

Replace packing.

Excessive clearance between cylinder tube and wear ring.

Replace wear ring (included in packing kit).

POSSIBLE CAUSE

PROCEDURE OR ACTION

HYDRAULIC PUMP PROBLEM Pump not delivering oil.

Pump pressure fails to rise.

Pump does not draw oil.

Check pump, piping, and valves for leaks.

Low oil level in reservoir.

Check fluid level.

Clogged screen at pump inlet.

Change oil and clean screen.

Improperly adjusted relief valve.

Increase to specified pressure using a pressure gauge.

Relief valve clogged.

Disassemble and clean with fresh oil.

Interfering relief valve or broken relief spring.

Disassemble valve and replace spring.

Air suction.

Check piping on suction side for leaks.

Add oil to reservoir.

Check pump seals.

15

Troubleshooting

PROBLEM Pump produces noise.

Abnormal temperature rise of hydraulic oil.

Pump case or drive gear broken.

16

1900 SRM 1506

POSSIBLE CAUSE

PROCEDURE OR ACTION

Cavitation caused by collapsed suction hose or clogged screen.

Drain and clean system.

Faulty oil suction.

Add oil to specified level.

Air suction through loose connections on suction side.

Tighten all hose connections on suction side.

Air suction from pump oil seal.

Disassemble pump and replace oil seals.

Breather clogged.

Clean or replace breather.

Cavitation caused by high oil viscosity.

Change to recommended oil and operate pump in recommended temperature ranges.

Overwork.

Adjust workload to fall within pump's operating range.

Improper viscosity or contaminated oil.

Drain and replace oil with recommended oil.

Incorrect pressure setting.

Check for excessive resistance in hydraulic circuit. Make certain relief pressure is properly adjusted and valve is working properly.

TECHNICAL PUBLICATIONS 1900 SRM 1506

2/15 (12/13)(6/11)

LIFTING MECHANISM P2.0 [A290]; W45ZHD [A419]

PART NO. 4035866

4000 SRM 1509

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR •

• • • • • • • • • • • • • •

The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the product. Updated technical service information may be available from your local authorized Hyster® dealer. Service Manuals provide general guidelines for maintenance and service and are intended for use by trained and experienced technicians. Failure to properly maintain equipment or to follow instructions contained in the Service Manual could result in damage to the products, personal injury, property damage or death.

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 when making 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.

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury and property damage.

On the lift truck, the WARNING symbol and word are on orange background. The CAUTION symbol and word are on yellow background.

Lifting Mechanism

Table of Contents

TABLE OF CONTENTS General .....................................................................................................................................................................1 Description of Operation .........................................................................................................................................1 Load Wheel .............................................................................................................................................................. 1 Remove ................................................................................................................................................................ 1 Install ...................................................................................................................................................................2 Caster Wheels ..........................................................................................................................................................3 Caster Adjustment ..............................................................................................................................................3 Caster Replacement ............................................................................................................................................4 Disassemble .................................................................................................................................................... 4 Assemble ......................................................................................................................................................... 5 Rear Link and Load Wheel Assembly .................................................................................................................... 5 Remove ................................................................................................................................................................ 5 Disassemble .........................................................................................................................................................6 Assemble ..............................................................................................................................................................6 Install ...................................................................................................................................................................6 Rocker Arm and Pull Rods ......................................................................................................................................6 Remove ................................................................................................................................................................ 6 Disassemble .........................................................................................................................................................9 Assemble ..............................................................................................................................................................9 Install ...................................................................................................................................................................9 Troubleshooting .....................................................................................................................................................10 This section is for the following models: P2.0 [A290]; (W45ZHD) [A419]

©2013 HYSTER COMPANY

i

"THE QUALITY KEEPERS" HYSTER APPROVED PARTS

4000 SRM 1509

General

General This section contains the description, repair, and adjustment procedures for the lifting mechanisms installed on the P2.0W35ZHD, W45ZHD lift truck.

For troubleshooting and repairs on the hydraulic components, see Hydraulic System 1900SRM1506.

For troubleshooting and repairs on the electrical components see Electrical System 2200SRM1508.

See AC Motor Controller 2200SRM1507 for controller functions.

Description of Operation The lifting mechanism consists of: •

Lift cylinder, 1 each

•

Rocker arm, 1 each

•

Pull rods, 2 each

•

Load wheel assemblies, 2 each

•

Rear links (wheel support), 2 each

The lifting mechanism connects the main frame to the fork frame. The lift cylinder and rocker arms are parts that connect the main frame to the fork frame. The pull rods are installed between the rocker arm and the load wheel assemblies.

The lifting mechanism is operated by the lift pump and motor assembly. When the lift button on the control handle is depressed, the lift pump sends hydraulic fluid to the lift cylinder. The lift cylinder extends, lifting the fork frame. This action operates the rocker arm, which move the pull rods forward in the direction of the drive motor. The movement of the pull rods cause the rear links and load wheels to pivot down, lifting the rear of the fork frame. This helps lift the fork frame and keep the forks parallel with the ground.

NOTE: The lift linkage is not adjustable.

Load Wheel REMOVE 1. Move the lift truck to a safe and level area.

6. Unscrew the axle capscrew. Remove the load wheel with bushings, bearings, and the spacer.

See Figure 1 or Figure 2.

2. Use the lift button to raise the lift truck to its maximum height.

7. Remove the bushings from each end of the load wheel.

3. Put blocks under both forks and on both side (front and back) of the drive tire to prevent movement of the lift truck. See the section

8. Remove the bearings from each end of the load wheel. It may be necessary to use a brass drift punch to drive the bearings out of the load wheel.

•

Periodic Maintenance 8000SRM1510 for lift truck model A290

•

Periodic Maintenance 8000SRM1666 for lift truck model A419

4. Press the lower button to relieve pressure from the hydraulic system.

9. Remove the spacer from the inside the load wheel.

10. Remove all old lubricant from the load wheel.

Clean and inspect all parts. Replace all defective parts as necessary.

5. Turn the key switch to the OFF position and disconnect the battery.

1

Caster Wheels

4000 SRM 1509

INSTALL 1. Install one of the bearings into the load wheel and install the spacer.

2. Install the other bearing into the load wheel.

3. Install the bushings into both ends of the load wheel.

4. Align the load wheel assembly with the opening in the rear link.

5. Install the axle capscrew.

6. Connect the battery and turn the key switch to the ON position. Press the lift button to raise the front forks.

7. Remove the blocks from the lift truck and press the lower button to lower the forks.

8. Test operation of the lift truck before returning the truck to service.

1.

2.

3.

4.

5.

6.

BUSHING LEVER WASHER ROCKER PLATE BUSHING CAPSCREW

7.

8.

9.

10.

11.

LOAD WHEEL BUSHING BALL BEARING ROLLER SPACER

Figure 2. Tandem Load Wheel Assembly

1.

2.

3.

4.

2

BUSHING 5. ROLLER LEVER 6. SPACER BUSHING 7. LOAD WHEEL BALL BEARING 8. CAPSCREW Figure 1. Single Load Wheel Assembly

4000 SRM 1509

Caster Wheels

Caster Wheels CASTER ADJUSTMENT WARNING In normal operation, the casters should continuously contact the floor. As the drive tire wears, the frame will move closer to the floor and the casters will carry more of the load. If the casters are not periodically adjusted, they will bear too much of the lift truck's weight and reduce the load on the drive tire necessary to maintain traction.

This can interfere with the drive tire's ability to control the steering and stopping functions of the truck.

Periodically, the casters must be adjusted to compensate for drive tire wear/replacement. Excess rocking is often a sign of under adjusted casters.

This may occur when a new drive tire is installed.

Loss of traction may be caused by over adjusted casters. This may occur when the drive tire diameter has decreased because of regular wear. The casters ideally should be level with the bottom of the drive tire (just touching the floor). A gap of not more than 1.50 mm (0.06 in.) between the caster wheels and the floor is acceptable, as is the casters being compressed to the floor not more than 1.50 mm (0.06 in.). Refer to the following instructions for the proper caster checking and adjustment procedures.

4. Loosen the wheel axle capscrews on either side of the caster wheel until the adjuster can be pulled away from the caster assembly clear of the adjustment pin. See Figure 3.

5. Rotate the adjuster up or down to adjust the caster wheel up or down.

6. Unless the drive wheel or caster wheel is being replaced, it should only be necessary to move the adjuster up or down one notch of the adjuster.

7. Push the adjuster into engage the adjustment pin.

8. Tighten the axle capscrews.

9. Remove the left truck from the blocks and check the casters for proper contact with the floor.

10. Connect the battery, turn the key switch to the ON position, and test for proper operation.

NOTE: The casters include an eccentric mounting of the caster wheels to facilitate adjustment.

1. Park the lift truck on a smooth and level surface with the control handle centered and with no load on the forks. Lower the forks completely.

2. Turn the key switch to the OFF position and disconnect the battery (DO NOT remove the battery).

3. Place the lift truck on blocks on both side of the drive frame. See •

Periodic Maintenance 8000SRM1510 for lift truck model A290

•

Periodic Maintenance 8000SRM1666 for lift truck model A419

1. ADJUSTMENT PIN 2. ADJUSTER 3. AXLE CAPSCREW Figure 3. Caster Adjustment

3

Caster Wheels

CASTER REPLACEMENT WARNING Put blocks under both forks and on both sides of the drive tire. The blocks must prevent the lift truck from falling and causing personal injury or property damage.

1. To remove the caster, park the lift truck on a smooth and level surface. Turn the key switch to the OFF position, and disconnect the battery.

2. Raise the drive wheel off the floor. Block the lift truck. See the section •

Periodic Maintenance 8000SRM1510 for lift truck model A290

•

Periodic Maintenance 8000SRM1666 for lift truck model A419

4000 SRM 1509 2. Remove the axle capscrews and the adjusters from the caster. Drive the axle from the caster wheel and remove the wheel. See Figure 4.

3. Remove the dust caps, spacers, bearings, and bushing from the caster wheel.

NOTE: If necessary, the wheel frame can be separated from the pivot frame by removing the pivot bolt. This should only be required if servicing the caster springs.

4. Remove the plug from the top of the caster assembly and remove the retaining ring.

5. Separate the top plate from the pivot frame.

6. Remove the retaining ring from the bottom of the top plate and remove the bearing.

3. Remove the four screws, nuts, and washers retaining the caster to the frame. Remove the caster wheel.

NOTE: The caster does not have to be removed from the lift truck frame in order to replace the wheel or the wheel axle. To replace the wheel or wheel axle, follow these steps: a. Remove the axle capscrew and adjuster from one side of the caster. Drive the wheel axle/ adjuster out of the caster wheel and remove the wheel from the caster frame. See Figure 4. b. Align the caster wheel between the arms of the caster frame and install the axle/adjuster into the caster frame and the caster wheel.

Install the adjuster and axle capscrew.

Tighten the capscrew to 35 N•m (25 lbf ft).

4. To reinstall the caster, align the caster with the holes in the frame and install the four screws.

Tighten the nuts to 56 to 58 N•m (41 to 43 lbf ft).

5. Repeat procedure to replace the second caster, if necessary.

Disassemble 1. Remove the caster wheel from the frame. Refer to Caster Replacement in this section.

4

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

PLATE 11. PIN FORK 12. ADJUSTER FORK 13. WHEEL CAPSCREW 14. TUBE LOCKNUT 15. BEARING SPRING 16. AXLE BALL BEARING 17. TUBE SNAP RING 18. SCREW SNAP RING 19. GUARD CAP Figure 4. Caster Wheel

4000 SRM 1509

Rear Link and Load Wheel Assembly

Assemble 1. Install the bearing in the top plate and install the retaining ring.

2. Install the top plate onto the pivot frame. Install the retaining ring and dust plug.

3. If removed, install the wheel frame into the pivot frame. Install the pivot bolt and tighten the lock nut to 85 N•m (63 lbf ft).

5. Align the caster wheel within the wheel frame and insert the axle.

6. Install the adjusters into the wheel frame and lock in place with the axle capscrews.

7. Align the four holes in the top plate with the holes in the lift truck frame. Install the capscrews, washers, and nuts removed during disassembly.

4. Install the dust covers, spacers, bearings, and bushing into the caster wheel.

Rear Link and Load Wheel Assembly REMOVE 1. Move the lift truck to a safe and level area.

2. Use the lift button to raise the lift truck to its maximum height.

3. Put blocks under both forks and on both side (front and back) of the drive tire to prevent movement of the lift truck. See the section •

Periodic Maintenance 8000SRM1510 for lift truck model A290

•

Periodic Maintenance 8000SRM1666 for lift truck model A419

4. Press the lower button to relieve pressure from the hydraulic system.

5. Turn the key switch to the OFF position and disconnect the battery.

6. Remove the capscrew retaining the rear link pivot pin to the fork frame. See Figure 5.

7. Remove the rear link pivot pin. This will allow the rear link to drop below the fork frame and allow the removal of the pull rod pin.

8. Drive the retaining pin out of the rear link and remove the pull rod pin. See Figure 6.

1. REAR LINK PIVOT PIN 2. CAPSCREW Figure 5. Fork Pin Removal

9. Remove the rear link and load wheel assembly from the lift truck.

5

Rocker Arm and Pull Rods

4000 SRM 1509

DISASSEMBLE

•

1. Remove the bushings from the rear link. See Figure 1 and Figure 2.

2. Remove the load wheel assembly from the rear link. See Load Wheel in this section to service the load wheel assembly.

ASSEMBLE 1. Press new bushings into the rear link. Using the grease fitting hole as a guide, align the groove in the bushing with the hole in the rear link casting.

Periodic Maintenance 8000SRM1666 for lift truck model A419

4. Connect the battery and press the lift button to raise the forks.

5. Remove the blocks from under the forks and the drive tire. Lower the truck.

6. Test the operation of the lift truck before returning the truck to service.

2. Assemble the load wheel assembly. See Load Wheel in this section for assembly instructions.

INSTALL 1. Align the pull rod with the rear link and install the pull rod pivot pin. Align the retaining pin hole in the pivot pin with the opening in the casting. Install the retaining pin into the rear link casting and through the hole in the pull rod pivot pin.

2. Align the rear link with the fork frame and install the rear link pivot pin. Install the retaining capscrew into the fork frame.

3. Lubricate all linkage pivot pins with multipurpose grease. See the Recommended Schedule of Maintenance in the section •

Periodic Maintenance 8000SRM1510 for lift truck model A290

1.

2.

3.

4.

5.

ROLL PIN PULL ROD PIN PULL ROD LOAD WHEEL ASSEMBLY REAR LINK Figure 6. Pivot Pin Removal

Rocker Arm and Pull Rods REMOVE WARNING When performing service that will require rocker arm to be removed, the main frame fork frame must be securely supported so they cannot lower or tilt when the linkage is connected.

the and that dis-

WARNING Batteries are heavy. Use care when working near or moving to avoid injury.

6

DO NOT put hands, arms, feet, and/or legs between the battery and a solid object. Make sure the capacity of the lifting device and spreader bar is greater than the weight of the battery. The weight of the battery is normally shown on the battery case. The maximum battery weight is shown on the lift truck nameplate. The spreader bar must NOT be made of metal or it must have insulated straps.

1. Move the lift truck to a safe and level area.

2. Use the lift button to raise the forks to maximum height.

4000 SRM 1509

Rocker Arm and Pull Rods

3. When performing service that will require the rocker arms or the upper links to be removed, put a solid wood or metal block under each side of the main frame, near the rocker arms. The blocks must be thick enough to just fit under the main frame. The main frame must not lower or tilt when the rocker arms or upper links are disconnected. Put blocks under both forks and on both sides of the drive tire. See the section •

Periodic Maintenance 8000SRM1510 for lift truck model A290

•

Periodic Maintenance 8000SRM1666 for lift truck model A419

See the section •

Periodic Maintenance 8000SRM1510 for lift truck model A290

•

Periodic Maintenance 8000SRM1666 for lift truck model A419

5. Separate the frame. See the section •

Frame 0100SRM1502 for lift truck model A290

•

Frame 0100SRM1665 for lift truck model A419

See Figure 7.

4. Turn the key switch to the OFF position and disconnect the battery. Remove the battery.

1. CAPSCREW

2. PIN Figure 7. Frame Separation

7

Rocker Arm and Pull Rods

CAUTION The rocker arm is heavy (11 kg). Support the rocker arm assembly during removal.

4000 SRM 1509 11. Remove the retaining pins from the load wheel assembly and remove the pull rod pins. Separate the pull rods from the load wheel assemblies.

6. Remove the capscrews retaining the load wheel assemblies to the fork frame. Remove the load wheel assembly pivot pins from the fork frame.

See Figure 8.

1. FORK

2. LIFT LINKAGE Figure 9. Lift Linkage Removal

1. CAPSCREW 2. LOAD WHEEL PIVOT PIN 3. ROCKER ARM PIVOT PIN Figure 8. Pivot Pin Removal 7. Remove the capscrews retaining the rocker arm pivot pins to the fork frame. Remove the rocker arm pivot pins.

8. Remove the lift linkage assembly from the fork frame. See Figure 9.

9. Remove the capscrews retaining the pull rod pins to the rocker arm assembly. See Figure 10.

10. Remove the pull rod pins and separate the pull rods from the rocker arm assembly.

1. RETAINING PIN 2. PIVOT PIN

3. PIVOT PIN 4. CAPSCREW

Figure 10. Pull Rod Pin Removal

8

4000 SRM 1509

DISASSEMBLE 1. Remove the bushings from each end of the pull rods and rocker arm. See Figure 11.

Troubleshooting 3. Align the rocker arm assembly with the pull rods attached with pivot pins holes in the fork frame.

4. Install the rocker arm pivot pins into the fork frame and rocker arm assembly.

5. Align the load wheel assembly with the pull rod end and install the pull rod pivot pins. Install the retaining pin into the load wheel assembly and through the pull rod pivot pin.

6. Align the load wheel assembly and pull rod with the load wheel pivot pin hole in the fork frame.

7. Install the load wheel pivot pins and the capscrews to retain the pivot pins to the fork frame.

1. ROCKER ARM 2. BUSHING 3. REAR LINK ASSEMBLY Figure 11. Lift Linkage Disassembly

ASSEMBLE 1. Press new bushings into the rocker arm. Align the groove in bushings with the lube fitting for each bushing.

2. Press new bushings into the pull rod ends. Insure the bushings are pressed flush with the pull rod end.

INSTALL 1. Insert the front of the pull rod into the rocker arm assembly and install the pull rod pivot pins.

2. Install the capscrews to retain the pull rod pivot pins.

8. Lubricate the load wheel assemblies and all linkage pivot pins with multipurpose grease.

For proper lubrication specifications, see the section: •

Periodic Maintenance 8000SRM1510 for lift truck model A290

•

Periodic Maintenance 8000SRM1666 for lift truck model A419

9. Assemble the frames. See the section •

Frame 0100SRM1502 for lift truck model A290

•

Frame 0100SRM1665 for lift truck model A419

10. Remove the blocks from the lift truck and install the battery. See the section •

Periodic Maintenance 8000SRM1510 for lift truck model A290

•

Periodic Maintenance 8000SRM1666 for lift truck model A419

11. Test the operation of the lift truck before returning the truck to service.

CAUTION The rocker arm is heavy (11 kg). Support the rocker arm assembly during installation.

9

Troubleshooting

4000 SRM 1509

Troubleshooting PROBLEM Forks fail to elevate.

Slow lifting speed and insufficient handling capacity.

10

POSSIBLE CAUSE

PROCEDURE OR ACTION

Battery is discharged.

Charge or replace battery. See the section Periodic Maintenance for your lift truck.

Oil in the hydraulic reservoir is low.

Fill reservoir to correct level.

Check for leaks. See the section Hydraulic System 1900SRM1506.

Faulty hydraulic equipment.

See the section Hydraulic System 1900SRM1506.

Deformed lifting components.

Disassemble and replace damaged parts.

Load exceeds lifting capacity.

Select loads within capacity rating.

Lift switch not operating properly.

Troubleshoot lift switch and wiring.

Battery is discharged.

Charge or replace battery. See the section Periodic Maintenance for your lift truck.

Oil in the hydraulic reservoir is low.

Fill reservoir to correct level.

Check for leaks. See the section Hydraulic System 1900SRM1506.

Faulty hydraulic equipment.

See the section Hydraulic System 1900SRM1506.

Deformed lifting components.

Disassemble and replace damaged parts.

Load exceeds lifting capacity.

Select loads within capacity rating.

4000 SRM 1509

PROBLEM Forks fail to lower.

Troubleshooting

POSSIBLE CAUSE

PROCEDURE OR ACTION

Battery is discharged.

Charge or replace battery. See the section Periodic Maintenance for your lift truck.

Deformed forks.

Disassemble, repair, or replace.

Deformed lifting components.

Disassemble, repair, or replace.

Bent lift cylinder piston rod.

See the section Hydraulic System 1900SRM1506.

Lower switch or solenoid not operating properly.

Troubleshoot lower switch, lowering solenoid, and wiring.

11

NOTES

12

TECHNICAL PUBLICATIONS 4000 SRM 1509

12/13 (6/11)

PERIODIC MAINTENANCE W45ZD [A419]

PART NO. 4099865

8000 SRM 1666

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR •

• • • • • • • • • • • • • •

The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the product. Updated technical service information may be available from your local authorized Hyster® dealer. Service Manuals provide general guidelines for maintenance and service and are intended for use by trained and experienced technicians. Failure to properly maintain equipment or to follow instructions contained in the Service Manual could result in damage to the products, personal injury, property damage or death.

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 when making 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.

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury and property damage.

On the lift truck, the WARNING symbol and word are on orange background. The CAUTION symbol and word are on yellow background.

Table of Contents

TABLE OF CONTENTS Introduction ............................................................................................................................................................. 1 General ................................................................................................................................................................ 1 Drive Unit Compartment Covers ....................................................................................................................... 2 How to Move a Disabled Truck .......................................................................................................................... 2 How to Tow the Lift Truck ............................................................................................................................. 2 How to Put the Truck on Blocks .........................................................................................................................4 How to Raise Drive/Steer Tire ....................................................................................................................... 4 How to Raise the Load Wheels ...................................................................................................................... 4 Special Precautions ................................................................................................................................................. 5 Discharging Capacitors .......................................................................................................................................5 Maintenance Schedule ............................................................................................................................................ 6 Maintenance Procedures Every 8 Hours or Daily ................................................................................................. 8 CHECKS WITH KEY SWITCH TURNED OFF ........................................................................................... 8 Safety Labels .............................................................................................................................................. 8 Battery ........................................................................................................................................................ 8 Oil Leaks .....................................................................................................................................................9 Drive Tire, Load Wheels, Casters, and Frame ......................................................................................... 9 CHECKS WITH KEY SWITCH TURNED ON ...........................................................................................10 Operation .................................................................................................................................................. 10 Maintenance Procedures Every 350 Hours or Every 2 Months ..........................................................................11 Battery ...........................................................................................................................................................11 HYDRAULIC SYSTEM ................................................................................................................................12 Hydraulic Oil ............................................................................................................................................ 12 CASTER LUBRICATION .................................................................................................................................12 DRIVE TIRE CHECK .......................................................................................................................................13 Maintenance Procedures Every 2000 Hours or Yearly ....................................................................................... 13 HYDRAULIC SYSTEM .................................................................................................................................... 13 Oil Change .................................................................................................................................................... 13 ELECTRICAL ................................................................................................................................................... 14 Battery Maintenance ............................................................................................................................................ 14 HOW TO CHARGE THE BATTERY ............................................................................................................... 14 Equalizing Charge ........................................................................................................................................ 15 Normal Charge ............................................................................................................................................. 15 HOW TO CHANGE THE BATTERY ...............................................................................................................15 Changing Battery With Rollers ................................................................................................................... 16 Remove ......................................................................................................................................................16 Install ........................................................................................................................................................17 This section is for the following models: (W45ZD) [A419]

©2015 HYSTER COMPANY

i

"THE QUALITY KEEPERS" HYSTER APPROVED PARTS

8000 SRM 1666

Introduction

Introduction GENERAL This section contains the instructions for periodic maintenance and inspection and a Maintenance Schedule.

The Maintenance Schedule has time intervals for inspection, lubrication, and periodic maintenance.

The time intervals are based on normal operation.

Normal operation is considered to be one 8-hour shift per day in a relatively clean environment on an improved surface. Multiple shifts, dirty operating conditions, etc., will require a reduction in the recommended time periods in the Maintenance Schedule.

WARNING DO NOT make repairs or adjustments unless you have been properly trained and authorized to do so. Improper repairs and adjustments can create dangerous operating conditions.

A. LH SIDE B. RH SIDE

DO NOT operate a truck that needs repairs. If repair is necessary, attach a DO NOT OPERATE tag to the control handle. Report the need for repairs to your supervisor immediately.

Some users have service personnel and facilities to perform the procedures listed in the Maintenance Schedule. Service Manuals are available from your Hyster™ lift truck dealer to help users who do their own repairs.

Your Hyster™ lift truck dealer has the trained personnel and equipment to conduct a complete program of inspection, lubrication, and maintenance. This program will help maximize your truck's performance and reliability.

NOTE: The front end of the truck is the control handle end. Forward travel refers to movement in the direction of the control handle with the load wheels trailing. Reverse is travel in the direction of the forks with the drive tire trailing. Left and right refer to the operator's left- and right-hand sides when standing on the truck, driving in the forward direction. See Figure 1.

C. FORKS TRAILING D. FORKS LEADING Figure 1. Truck Orientation 1

Introduction

DRIVE UNIT COMPARTMENT COVERS The drive unit compartment is concealed behind a molded cover which fits securely around the drive unit and steer support to the frame.

To remove the drive unit cover, start at the top left edge of the cover and with both hands pull the cover away from the frame until the cover kicks out from the retaining clips. Repeat this for the right side of the cover. Work around the edge of the cover umtil free from the truck. See Figure 2.

To install drive unit cover, place the bottom of the drive unit cover onto the frame and position the lower edges partially into the lower retaining clips.

Align holes in the in the cover with alignmnet pins attached to farme. Push the top of the cover partially into the upper retaining clips. Do not push either edge of the cover in completely in before starting all edges into the proper place. When the cover is aligned and started properly, press the cover completely into the retaining clips. See Figure 2.

HOW TO MOVE A DISABLED TRUCK This lift truck is not normally towed. If the traction system will not operate, make repairs at the location, if possible. If the truck must be towed, refer to Step 1 in this section.

WARNING Never carry a disabled truck unless it MUST be moved and cannot be towed. The lift truck used to lift the disabled truck MUST have a rated capacity equal to or greater than the weight of the truck.

See the nameplate on the truck for the approximate total weight. The fork spread must be equal to half the width of the disabled truck. The forks must extend the full width of the disabled truck. Put the weight of the disabled truck at the center of the forks and be careful not to damage the underside of it. Tilt the mast back and travel slowly.

Make sure no one except the driver is near the lift trucks during towing. Both the tow truck and the disabled truck can cause a personal injury during towing.

2

8000 SRM 1666 To avoid personal injury, use extra care when moving a lift truck during the following conditions: •

Brake does not operate correctly

•

Steering does not operate correctly

•

Tire is damaged

•

Traction conditions are bad

CAUTION Never carry the lift truck faster than the speed of a person walking. Steering can be difficult and motor damage can occur at higher speeds.

Always travel smoothly without sudden starts.

The electric brake must be released before the lift truck can be moved. If there is not sufficient battery power, placing the control handle in the operating position will not release the electric brake. Refer to the Step 1 section of this manual.

Use the control handle to steer the lift truck while it is being towed. Use one hand and walk to one side of the lift truck. DO NOT walk or stand between the towing vehicle and the lift truck.

How to Tow the Lift Truck

WARNING Stay clear of the tow chain, towing vehicle, and lift truck during the towing operation to prevent personal injury.

Make sure no one, except the driver, is near the lift trucks during towing. Both the tow truck and the disabled truck can cause personal injury during towing.

If there is no power, the drive wheel will not turn freely. Poor traction can cause the disabled truck or towing vehicle to slide. Grades will require additional distance to stop.

CAUTION Travel slowly and DO NOT tow on grades. NEVER tow the lift truck faster than a normal walking speed. Always tow smoothly, without sudden starts or stops.

8000 SRM 1666

Introduction

Until repairs are complete, keep a tag on the control handle stating DO NOT OPERATE. Remove the key.

NOTE: The Brake Release Adapter MUST be removed after repairs are completed BEFORE returning the truck to service.

1. Disconnect the battery, and fasten the chain to the lift truck. Make sure the tow chain has the capacity to tow the weight. Carefully fasten the tow chain completely around the drive unit compartment and battery compartment over top of the forks. The chain must not cause damage to either lift truck.

3. Steer the lift truck with the control handle while it is being towed. Use one hand and walk to one side of the lift truck. DO NOT walk or stand between the towing vehicle and the lift truck.

2. The electric brake must be released before the lift truck can be towed. If there is not sufficient battery power, placing the control handle in the operating position will not release the electric brake.

When there is no alternative, the brake assembly may be removed from the traction motor to allow towing. For brake removal procedures see Brakes 1800SRM1505.

1. DRIVE UNIT COMPARTMENT COVER 2. ALIGNMENT PIN

4. Tow the lift truck slowly.

5. If counterbalanced style, lift truck configured with the drive wheels nearest to the forks is used to tow the disabled lift truck. The lift truck must have weight added to the forks. The total weight of the lift truck and load must be equal to or greater than the weight of the disabled lift truck. Install a load of approximately half the maximum capacity on the forks of the lift truck that is used for towing. This load will increase the traction of the lift truck. Keep the load on the forks lowered as much as possible.

3. RETAINING CLIPS 4. FRAME

Figure 2. Drive Unit Compartment Cover

3

Introduction

8000 SRM 1666

If counterbalanced style, lift truck configured with the drive wheel(s) furthest from the forks is used to tow the disabled lift truck. DO NOT add weight to the forks. Additional weight on the forks may DECREASE the traction of the drive wheel(s). Make sure that the lift truck used has a total weight equal to or greater than the weight of the disabled lift truck.

HOW TO PUT THE TRUCK ON BLOCKS WARNING DO NOT put the truck on blocks if the surface is not solid, even, and level. Make sure that any blocks used to support the truck are solid, onepiece units. Put a block in front and back of the tires touching the ground to prevent movement of the lift truck.

DO NOT raise the truck by attaching an overhead lifting device to areas that can be damaged. Some points of the truck are not designed to support the weight of the truck. The truck can be damaged or it can fall, causing serious injury. Attach the chain or sling to a support structure of the lift truck frame.

2. Use a special low clearance hydraulic jack, crane, or another lift truck to raise the drive tire. Make sure that the jack, crane, or other lift truck has the correct capacity rating. The capacity must equal to 2/3 the weight of the lift truck, including the battery. See the capacity plate.

3. Raise the lift truck only enough to suspend the drive tire. Install additional blocks under the frame near the drive tire.

How to Raise the Load Wheels

WARNING Never raise the forks any higher than necessary to change the load wheels. Always raise both forks at the same time. Raising the forks too high can make the lift truck tip over and cause property damage or personal injury.

1. Put blocks on both sides (front and back) of the drive tire to preventmovement of the lift truck.

How to Raise Drive/Steer Tire

2. Use an overhead crane and web sling under the forks to raise the load wheels. Another lift truck can also be used to raise the forks. Make sure that the crane and sling or other lift truck has a capacity of at least 2/3 the total weight of the lift truck, as shown on the capacity plate.

1. Put blocks on each side (front and back) of the loadwheels to prevent movement of the lift truck.

3. Raise the forks only enough to suspend the wheels. Install blocks under the forks at the rear of the wheels to support the lift truck.

See Figure 3.

Figure 3. Putting Lift Truck on Blocks

4

8000 SRM 1666

Special Precautions

Special Precautions DISCHARGING CAPACITORS WARNING The capacitor in the controller can hold an electrical charge after the battery is disconnected. To prevent electrical shock and personal injury, discharge the capacitor before inspecting or repairing any component. Wear safety glasses. Make certain the battery has been disconnected. DO NOT use a screwdriver to discharge the traction motor controller.

WARNING To avoid personal injury and prevent electrical shock, perform the following steps before performing any troubleshooting or adjustments, and connecting or disconnecting a handset or PC.

CAUTION To avoid controller damage, always disconnect the battery. Discharge the capacitor and never put power to the controller with any power wire disconnected. Never short any controller terminal or motor terminal to battery. Make sure to use proper procedures when servicing the controller.

1. Move the truck to a safe, level area. Turn the key switch to the OFF position and disconnect the battery.

2. Remove the drive unit compartment cover to access the drive unit compartment.

3. Discharge the capacitor in the controller by connecting a 200-ohm, 2-watt resistor across the controllers B+ and B terminals using insulated jumper wires. See Figure 4. DO NOT short across the motor controller terminals with a screwdriver or jumper wire.

1.

2.

3.

4.

5.

CONTROLLER POSITIVE CONNECTION INSULATED JUMPER WIRES 200-OHM, 2-WATT RESISTOR NEGATIVE CONNECTION Figure 4. Discharging Capacitors

5

Maintenance Schedule

8000 SRM 1666

Maintenance Schedule The Maintenance Schedule is divided into three time intervals which call for particular maintenance procedures to be performed. The intervals are 1 Day or 8 Hours, 2 Months or 350 Hours, and 1 Year or 2000 Hours for normal operation (whichever comes first). Normal operation is considered one 8-hour shift per day, in a relatively clean environment, on an improved surface. Operating a lift truck for more than eight hours per day is consid-

ered Heavy operation and requires the 2-month/ 350-hour checks to be performed at 1 month/200 hours. Lift trucks operating in freezer environments or dirty conditions are considered Severe operation and require the 2-month/350-hour checks to be performed at 1 month/200 hours. The approximate locations of the items listed in the Maintenance Schedule are shown in Figure 5.

Figure 5. Maintenance Points Table 1. Maintenance Schedule (See Figure 5) Item No.

Item

8 350 Hr/ Hr/ 2 1 mont day h5

2000 Hr/ 1 year5

Procedure or Quantity

Specification

Check Level

See Specifications Hold on 10% Grade4

5

1

Battery

X

2

Brake

X

Check Operation

3

Directional/Speed Control

X

Check Operation

4

Gauges, Horn, and Fuses

X

Check Operation

X7

X=Check C=Change L=Lubricate NOTE: Never use steam to clean electrical parts.

6

8000 SRM 1666

Maintenance Schedule Table 1. Maintenance Schedule (See Figure 5) (Continued)

Item No.

Item

8 350 Hr/ Hr/ 2 1 mont day h5

2000 Hr/ 1 year5

Procedure or Quantity

C

Maximum 0.75 liter (0.79 qt)

Specification

5

5

Hydraulic Oil (Full Mark)

X6

Minimum 0.6 liter (0.63 qt) Standard

0 to 48°C (32 to 120°F) 1

Cold Storage/Freezer

-18 to 48°C (0 to 120°F) 2

Sub-Zero

-40 to 48°C (-40 to 120°F)

6

Oil Leaks

X

Check for Leaks

7

Lift, Lower Operation

X

Check Operation

8

Safety Labels and Operating Manual

X

Replace if Necessary

9

Steering Operation

X

Check Operation

10

Tires, Wheels, and Casters

X

Check Condition

11

Contactor Tips

X

Check Condition

Non-Servicable

12

Lubrication Fittings

L

Lubricate

Standard8

See Parts Manual

Cold Storage/Freezer3 13

Wheel Bolt Torque

X

Tighten if Required

120 N•m (88 lbf ft)

1

Chevron EP Hydraulic Oil 68 or equivalant.

2

Exxon Univis HV126 or equivalant.

3

For freezer or cold storage operation, MIL-G-7711A.

4

With rated load.

5

Whichever comes first.

6

7

Hydraulic oil changed at initial 350 hour interval.

Equalization Charge approximately each month but not more than each week.

8

Multipurpose Grease with 2-4% Molybdenum Disulfate for normal operations.

X=Check C=Change L=Lubricate NOTE: Never use steam to clean electrical parts.

7

Maintenance Procedures Every 8 Hours or Daily

8000 SRM 1666

Maintenance Procedures Every 8 Hours or Daily WARNING DO NOT operate a lift truck that needs repairs. If a repair is necessary, attach a DO NOT OPERATE tag to the control handle and disconnect the battery.

Inspect the lift truck every 8 hours or daily before use. Put the lift truck on a level surface. Lower the carriage and forks, and turn the key switch to OFF. If repair is required, attach a DO NOT OPERATE tag to the control handle and disconnect the battery. DO NOT operate a lift truck until the problems are corrected.

CHECKS WITH KEY SWITCH TURNED OFF Make the following checks: •

Electrolyte and specifici gravity of the battery.

•

Make sure the battery is clean and the correct size and weight for the lift truck.

•

Check that the battery restraint plates are in place.

•

Leaks in the hydraulic system.

•

Condition of the casters, load wheels, drive tire, and frame.

Safety Labels

WARNING If labels that have warnings or instructions are damaged, they must be replaced immediately.

Check that all safety labels are installed in the correct locations on the lift truck. Make sure that all labels are not damaged and that they can be read. If necessary, see the Parts Manual for your lift truck for the correct location of the labels.

Safety labels are installed on the lift truck to give information about possible hazards. It is important that all safety labels are installed on the lift truck and can be read. See the Parts Manual for label placement for your lift truck.

8

Battery

WARNING DO NOT lay tools on top of the battery.

The acid in the electrolyte can cause injury. If the electrolyte is spilled, use water to flush the area.

Make the acid neutral with a solution of sodium bicarbonate (baking soda). Acid in the eyes must be flushed with water continuously for fifteen minutes then seek medical attention.

Batteries generate explosive fumes. Keep the vents in the caps clean. Keep sparks or open flames away from the battery area. DO NOT make a spark from the battery connections. Disconnect the battery when doing maintenance.

The battery must fit the battery compartment so the battery restraint panelswill operate correctly.

Use spacers to prevent the battery from moving more than 13 mm (0.5 in.) in any direction.

CAUTION Disposal of batteries must meet local environmental regulations.

Make sure the batteryweight is within themaximum and minimum weight shown on the nameplate.

Keep the battery case, top cover, and the area for the battery clean and painted. Leakage and corrosion from the battery can cause a malfunction in the electric controls of the lift truck. Use a water and sodium bicarbonate solution (soda) to clean the battery and the battery area. Keep the top of the battery clean, dry, and free of corrosion.

Make sure the battery is charged and has the correct voltage and ampere hour rating for the lift truck. See the nameplate.

Inspect the battery case, connector, and cables for damage, cracks, or breaks. Contact your local battery dealer to discuss repair options for the battery case. Check the level of the electrolyte daily on aminimum of one cell. The correct level is halfway between the top of the plates and the bottom of the fill hole. Add only distilled water.

8000 SRM 1666 Make certain the battery restraint panels are properly installed.

Maintenance Procedures Every 8 Hours or Daily

Drive Tire, Load Wheels, Casters, and Frame

WARNING WARNING Make sure the key switch is OFF and the brake is set before connecting the battery.

If the lift truck was operated with a discharged battery, check the contactor for welded tips before a charged battery is connected.

The battery should have an equalization charge each month, but notmore than each week.

Oil Leaks

WARNING Always wear the proper protective equipment including eye protection and petroleum-resistant gloves when handling hydraulic oil. Thoroughly wash oil from exposed areas of skin as soon as possible.

Completely lower forks to relieve hydraulic pressure before disassembling any part of the lift pump or disconnecting any hydraulic hoses.

When the drive tire has been installed, check all wheel nuts after 2 to 5 hours of operation. When the nuts stay tight after an 8-hour check, the interval for checking the torque can be extended to 350 hours. Refer to the Maintenance Schedule in this section.

If the drive tire has recently been installed, check to ensure the lug nuts are properly tightened to 191 to 210 N•m (141 to 155 lbf ft). When installing, snug all the nuts, then tighten to half the torque value, then tighten to the full torque value. Tighten the nuts in a cross pattern to properly seat the wheel to the hub.

Inspect the tire for embedded rocks, glass, wire, pieces of metal, holes, cuts, and other damage. See Figure 6. Remove any object that will cause damage. Check for loose or missing nuts and broken studs. Remove any wire strapping or other material that is wrapped around the axle to prevent damage to the axle seal.

The hydraulic oil is hot at normal operating temperatures. Be careful when draining the oil.

Never check for leaks by putting hands on hydraulic lines or components under pressure. Hydraulic oil under pressure can be injected into the skin.

CAUTION Protect the hydraulic system from dirt and contaminants when servicing the hydraulic system.

Never operate the pump without the proper amount of oil in the hydraulic system. The operation of the hydraulic pump with low oil levels will damage the pump.

Check for leaks by looking for oil under the lift truck and where the lift truck has been parked.

Visually inspect the hydraulic system and hoses.

Small oil leaks may appear as wet, oily leaks or unusually dirty areas where dirt and dust sticks to oil that has slowly leaked out.

1. REMOVE EMBEDDED OBJECTS 2. CHECK FOR CUTS, SPLITS, AND OTHER DAMAGE Figure 6. Tire Check

9

Maintenance Procedures Every 8 Hours or Daily Inspect the frame for structural damage and loose/ missing hardware. Make certain all covers are in place and secured before operating the lift truck.

Inspect the load wheels. Loose or crooked load wheels may indicate a bearing failure. If failure is suspected, raise the lift truck slightly and check that the load wheels are secure on the axles and rotate smoothly. See How to Put a Lift Truck on Blocks. Repair or replace as necessary.

WARNING In normal operation, the casters should continuously contact the floor. As the drive tire wears, the frame will move closer to the floor and the casters will carry more of the load. If the caster shims are not periodically adjusted, they will bear too much of the lift truck weight and reduce the necessary load on the drive tire. This can interfere with the ability of the drive tire to control steering and stopping functions of the truck.

To check for proper adjustment see Caster Adjustment Check in this section.

WARNING Safety labels are installed on the lift truck to give information about possible hazards. It is important that all safety labels are installed on the lift truck and can be read.

Check that all safety labels are installed in the correct locations on the lift truck. See the Parts Manual or the section Frame 0100SRM1665 for the proper locations of the safety labels.

Check the frame channel for excessive wear in the areas of roller contact. Check the rollers for wear or damage. Check the load backrest extension for cracks and damage. Make sure the nuts and bolts for the load backrest extension are tight.

CHECKS WITH KEY SWITCH TURNED ON Operation

WARNING Make sure the area around the lift truck is clear before moving the lift truck. Always look in the direction that you intend to move the lift truck. Be careful when making checks or servicing the lift truck.

10

8000 SRM 1666 Make sure a properly charged battery of the correct voltage is installed and connected. Turn the key switch to the ON position. Move the directional butterfly switch on the control handle head to test for proper forward and reverse travel operation.

WARNING Use the battery power disconnect to shut down the truck only in an emergency.

The key switch (or toggle switch) is a two position switch located on the right side of the dash display.

The first position is OFF (marked "O"). The second position is ON (marked "I"). The key switch should be used as the primary means of shutting down the truck.

WARNING Always wear the proper protective equipment including eye protection and petroleum-resistant gloves when handling hydraulic oil. Thoroughly wash oil from exposed areas of skin as soon as possible.

Completely lower the forks to relieve hydraulic pressure before disassembling any part of the lift pump or disconnecting any hydraulic hoses.

The hydraulic oil is hot at normal operating temperatures. Be careful when draining the oil.

Never put your hands on pressurized hydraulic components. Highly pressurized hydraulic oil escaping through pin-hole leaks can be injected into the skin. Visually inspect to find hydraulic leaks.

CAUTION Protect the hydraulic system from dirt and contaminants when servicing the hydraulic system.

Never operate the pump without the proper amount of oil in the hydraulic system. Operating the hydraulic pump with low oil levels will damage the pump.

1. Raise the forks slowly without a load. Check for smooth operation and mechanical interference.

Mechanical interference is caused by damaged or worn linkage or shafts or by incorrect adjustment of the tension rods.

8000 SRM 1666 2. Check for damaged or worn linkage bushings or shafts.

3. Check for missing or loose shaft pins.

4. Check load wheels and support bearings, shafts, and shaft pins for wear, damage, or missing parts.

WARNING If any function does not operate or operates incorrectly, remove the truck from operation and attach a DO NOT OPERATE tag to the control handle. Remove the key and disconnect the battery.

Test the lift truck operation in an area that is clear of personnel and equipment.

5. Check the operation of the key switch. Functions should not operate with the key in the OFF position. Turn the key to the ON position.

Lower the control handle to the operating (BRAKE OFF) position. The horn, hydraulic functions, traction functions, and brake should be operational.

6. Check the operation of the brake switch. Release the control handle to allow it to return to the vertical position. Rotate the directional control (butterfly) switch without lowering the control handle. The traction system must not operate under these conditions.

7. Check the operation of the directional control (butterfly) switch. Lower the control handle to release the brake. Slowly rotate the directional control (butterfly) switch in either direction.

Maintenance Procedures Every 8 Hours or Daily The lift truck must accelerate smoothly. Rotate the switch in the opposite direction. The lift truck must stop smoothly and then change direction. Check the control handle return spring.

The control arm should return to the full vertical position when the control handle is released.

8. Check the operation of the lift and lower functions. Push the lift button and then the lower button. Check that the forks raise and lower smoothly.

9. Check the operation of the traction reverse function. Slowly rotate the directional control (butterfly) switch in the reverse direction. Push the traction reverse button without changing the position of the directional control (butterfly) switch. The horn must sound and the lift truckmust stop and accelerate in the opposite direction. Once the lift truck changes direction and moves with the control handle trailing, release the traction reverse button. The lift truck should not resume movement in the direction of the control handle until the directional control (butterfly) switch is cycled back to the neutral position and then rotated in either direction or until the control handle is moved to the BRAKE ON position and then back to the BRAKE OFF position.

10. Check the steering function. Move the control handle to the right and left. Check for smooth movement of the drive tire in the same direction. Steering will require more effort on standard steer models if the lift truck is stationary.

Maintenance Procedures Every 350 Hours or Every 2 Months Battery

WARNING DO NOT lay tools on top of the battery.

The acid in the electrolyte can cause injury. If the electrolyte is spilled, make the acid neutral with a solution of sodium bicarbonate (soda) and water, then flush the area with water. Acid in the eyes must be immediately flushed with water continuously for 15 minutes, then seek medical attention.

Batteries generate explosive fumes. Keep the vents in the caps clean. Keep sparks or open flames away from the battery area. DO NOT make a spark from the battery connections. Disconnect the battery when performing maintenance.

The battery must fit the battery compartment so the battery restraint panels will operate correctly.

Use spacers to prevent the battery from moving more than 13.0 mm (0.5 in.) in any direction.

NOTE: Battery water levels can be maintained without removing the battery from the truck.

11

Maintenance Procedures Every 350 Hours or Every 2 Months Check for loose or broken electrical connections and damaged wires or cables. Examine the battery case for damage and leakage. See the battery dealer in the area to repair any damage to the battery or cables.

Check that the vent caps are clear. Check the level of the electrolyte daily on a minimum of one cell.

Add only distilled water, as necessary, if the cell is low. If one cell is low, check the rest of the cells.

The correct level is halfway between the top of the plates and the bottom of the fill hole. Use a hydrometer to check that the battery is not discharged below the minimum specific gravity given by the manufacturer and has enough charge to complete a work period. See How to Charge the Battery in this section.

8000 SRM 1666

The hydraulic oil is hot at normal operating temperatures. Be careful when draining the oil.

Never check for leaks by putting hands on hydraulic lines or components under pressure. Hydraulic oil under pressure can be injected into the skin.

CAUTION Protect the hydraulic system from dirt and contaminants when servicing the hydraulic system.

Never operate the pump without the proper amount of oil in the hydraulic system. The operation of the hydraulic pump with low oil levels will damage the pump.

Perform the following check.

Remove the battery as described in the section Industrial Battery 2240SRM0001. Check the battery case, connector, and cables for damage, cracks, or breaks. See the battery dealer in your area to repair any damage. Keep the battery case and the battery compartment clean and painted. Leaks and corrosion from the battery can cause a malfunction in the electric controls of the lift truck. Use a water and soda solution to clean the battery and the battery compartment. Keep the top of the battery clean, dry, and free of corrosion.

NOTE: The hydraulic oil should be changed after the initial 350 hour break-in period and then every 2000 hours thereafter. Refer to Maintenance Procedures Every 2000 Hours or Yearly for oil change procedures for the initial 500 hour change.

Make sure the battery is the correct weight and voltage size. Prevent side-to-side movement of the battery by adjusting the brackets on either side of the battery. The correct battery is specified in How to Change the Battery and in the Operating Manual. The Operating Manual is located in the container on the Drive Unit cover. This is a permanent reference and must be available for use at all times.

Remove drive unit cover. Remove breather cap from hydraulic pump and reservoir. Add hydraulic oil, if necessary, through the breather filler pipe until oil is at Full mark on reservoir. Install breather cap and tighten. DO NOT OVERFILL.

HYDRAULIC SYSTEM

WARNING Always wear the proper protective equipment including eye protection and petroleum-resistant gloves when handling hydraulic oil. Thoroughly wash oil from exposed areas of skin as soon as possible.

Completely lower forks to relieve hydraulic pressure before disassembling any part of the lift pump or disconnecting any hydraulic hoses.

12

Hydraulic Oil

Check the hydraulic oil level when the oil is at normal operating temperature and forks are in the lowered position.

CASTER LUBRICATION CAUTION Use only the recommended lubricants for your application. Refer to Capacities and Specifications 8000SRM1511 for lubrication specifications for your lift truck.

Wipe grease fittings clean before greasing.

NOTE: Some optional packages may utilize sealed bearings or different grease fitting configurations.

Contact your Hyster dealer for information on optional packages.

8000 SRM 1666

Maintenance Procedures Every 350 Hours or Every 2 Months

The casters should be lubricated every 350 hours or 2 Months during normal operation. The caster has one grease fitting in the top plate to lubricate the swivel bearing. See Figure 7.

1. SWIVEL MOUNT 2. CASTER WHEEL 3. ADJUSTER Figure 7. Heavy-Duty Caster

DRIVE TIRE CHECK WARNING When the drive tire has been installed, check all wheel bolts after 2 to 5 hours of operation. When the wheel bolts stay tight after an 8-hour check, the interval for checking the torque can be extended to 350 hours.

Check to ensure the wheel bolts or lug nuts are properly tightened to 200 ± 9 N•m (148 ± 7 lbf ft).

Inspect the tire for embedded rocks, glass, wire, pieces of metal, holes, cuts, and other damage. Remove any object that will cause damage. Check for loose or missing lug nuts or wheel bolts. Remove any wire strapping or other material that is wrapped around the axle to prevent damage to the axle seal. Make sure the wheel bolts are tight. When installing the tire and wheel, snug the wheel bolts, then tighten to half the torque value, then tighten to the full torque value. Tighten the nuts in a cross pattern to properly seat the wheel to the hub.

Maintenance Procedures Every 2000 Hours or Yearly HYDRAULIC SYSTEM Oil Change

WARNING Always wear the proper protective equipment including eye protection and petroleum-resistant gloves when handling hydraulic oil. Thoroughly wash oil from exposed areas of skin as soon as possible.

Completely lower forks to relieve hydraulic pressure before disassembling any part of the lift pump or disconnecting any hydraulic hoses.

The hydraulic oil is hot at normal operating temperatures. Be careful when draining the oil.

Never check for leaks by putting hands on hydraulic lines or components under pressure. Hydraulic oil under pressure can be injected into the skin.

CAUTION Protect the hydraulic system from dirt and contaminants when servicing the hydraulic system.

Never operate the pump without the proper amount of oil in the hydraulic system. The operation of the hydraulic pump with low oil levels will damage the pump.

NOTE: The hydraulic oil should be changed after the initial 350 hour break-in period and then every 2000 hours thereafter.

13

Maintenance Procedures Every 2000 Hours or Yearly

8000 SRM 1666

Lower the forks, turn the key switch to the OFF position, and disconnect the battery. Remove drive unit compartment cover. Remove the screws securing retaining brackets to the bottom of the lift pump. Slightly twist the reservoir from the hydraulic pump andmotor assembly to remove. Recover the reservoir O-ring. Empty hydraulic oil into a suitable container and discard in accordance with local regulations. Clean hydraulic reservoir using a suitable cleaning solution and dry with compressed air. Clean and inspect strainer. Replace strainer if clogged or damaged. Clean and check reservoir Oring for brittleness or damage. Replace as necessary.

clamps and secure using screws as removed. Add hydraulic oil through breather filler pipe until at Max mark on reservoir. Install breather cap and tighten. Raise and lower forks several times to bring the oil to normal operating temperature.

Then recheck hydraulic oil level. DO NOT OVERFILL. Reconnect the battery, turn the key switch to the ON position, and fully cycle the lift and lower functions several times to expel air from the hydraulic system. Recheck the hydraulic oil level and add as necessary. Reinstall the drive unit compartment covers and return to service.

Make sure reservoir is clean and dry. Lubricate the O-ring with a thin coating of grease and position it around the lip of the reservoir as removed. Install reservoir into the pump flange. If the O-ring shifts out of place during installation; stop, reposition the O-ring, and resume installation. Install retaining

Inspect all visible electrical wiring and terminals when performing these checks. Repair any areas where rubbing has frayed wiring. For more information on electrical systems, refer to section Electrical System 2200SRM1508.

ELECTRICAL

Battery Maintenance HOW TO CHARGE THE BATTERY WARNING DO NOT put tools on the battery.

If the lift truckwas operatedwith a lowbattery, check all contactors for welded contacts before a charged battery is connected.

Make sure the key switch is in the OFF position and the park brake is set before connecting the battery.

The acid in the electrolyte can cause injury. If the electrolyte is spilled, use water to flush the area.

Use a solution of sodium bicarbonate (soda) and water to make the acid neutral. Acid in the eyes must be immediately flushed with water continuously for 15 minutes, then seek medical attention.

Batteries generate explosive fumes. Keep the vents in the caps clean. Keep sparks or open flames away from the battery area. DO NOT make a spark from the battery connections. Disconnect the battery when doing maintenance.

14

CAUTION Never connect the battery charger plug to the plug of the lift truck. You can damage the electronic controller. Make sure the battery charger voltage is the correct voltage for the battery.

Correct use of the hydrometer and proper operation of the battery charger is important. Operate the battery charger according to the instructions of the charger manufacturer. Never let the battery discharge below the minimum value given by the battery manufacturer. A fully charged battery will have a specific gravity of 1.265 to 1.310 at 25°C (77°F). See Table 2. Never charge a battery at a rate that will raise the electrolyte temperature above 49°C (120°F). Never permit a battery to stay discharged for long periods.

8000 SRM 1666

Battery Maintenance

Table 2. Specific Gravity Corrections Specific Gravity Reading

Electrolyte Correction TemperaPoints ture

Correct Value

1.210

31°C (88°F)

+0.003

1.213

1.210

27°C (81°F)

+0.001

1.211

1.210

25°C (77°F)

+0.000

1.210

1.210

18°C (64°F)

-0.004

1.206

+0.001 for each 1.7°C (35°F) from the 25°C (77°F). Base Value (Degrees C x 1.8) + 32 = Degrees F.

battery if the battery is charged at regular intervals. Frequent charging of a battery that has a 2/3 or more charge can decrease the life of the battery.

HOW TO CHANGE THE BATTERY WARNING Make sure the capacity of the crane and spreader bar is greater than the weight of the battery. The weight of the battery is normally shown on the battery case. The spreader bar must NOT be made of metal or it must have insulated straps.

Equalizing Charge

Batteries are heavy. Use care to avoid injury.

NOTE: Many customers have battery chargers that can follow a program to automatically charge a battery according to recommendations of the battery manufacturer. Use the recommendations of the battery manufacturer for charging the battery. Use only battery chargers approved by the battery manufacturer or dealer.

The replacement battery must fit the battery compartment correctly. Use spacers to prevent the battery from moving in the battery compartment.

This charge is at a low rate and balances the charge in all of the cells. The equalizing charge is normally given approximately once a month. It is a charge at a slow rate for 3 to 6 hours in addition to the regular charging cycle.

DO NOT give an equalizing charge more than once a week. The most accurate specific gravity measurement for a charged battery will be after an equalizing charge. If the difference in specific gravity is more than 0.020 between cells of a battery after an equalizing charge, there may be a cell that has a malfunction. Consult your battery dealer.

Normal Charge NOTE: Many customers have battery chargers that can follow a program to automatically charge a battery according to recommendations of the battery manufacturer. Use the recommendations of the battery manufacturer for charging the battery. Use only battery chargers approved by the battery manufacturer or dealer.

This charge is normally given to a battery that is discharged from normal operation. Many customers charge the battery at regular intervals that depend on use. This procedure will keep the battery correctly charged if the battery is not discharged below the limit. Always use a hydrometer to check the

Make sure the weight of the replacement battery is within the maximum and minimum weights shown on the nameplate.

Make sure the key switch is in the OFF position and the park brake is set before connecting the battery.

CAUTION If the lift truck was operated using a low battery, inspect for welded contacts BEFORE connecting a charged battery. The circuit will not reset and lift truck operation cannot be controlled if the contacts arewelded. Prevent sideto- side movement of the battery by adjusting the brackets on each side of the battery and tighten the capscrews, lockwashers, and nuts to retain the batteries.

The replacement battery must fit the battery compartment. Make sure the battery cables have clearance to move during lifting and lowering of the forks. Make sure that the replacement battery is the correct voltage and weight as shown on the capacity plate. See Figure 8.

1. Turn the key switch to the OFF position. Disconnect the battery. Use a spreader bar and lifting device to remove the battery.

2. Position blocks under both sides of the truck in the area of the battery compartment.

3. Loosen and remove buckle and strap from around battery.

15

Battery Maintenance

8000 SRM 1666

Changing Battery With Rollers

WARNING Batteries are heavy and can cause an injury. Use care to avoid injury. DO NOT put hands, arms, feet, or legs between the battery and a solid object.

Always wear protective clothing, gloves, and goggles when handling batteries and electrolyte.

NOTE: The battery spacers used for the battery roller option are bolted onto the side gates and are not adjustable. Different spacers can be obtained for different width batteries.

Changing the battery with rollers should only be done on a level surface and with a properly functioning battery puller.

Remove 1.

2.

3.

4.

CRANE SPREADER BAR INSULATOR STRAPS BATTERY Figure 8. Changing the Battery

4. Lift the battery out of the truck. DO NOT allow the battery to shift from side to side. Make sure the battery cables have clearance.

5. Before installing a new battery, make sure the battery is the correct size and weight for the lift truck. Make sure the battery has clearance for installation. Check that the battery connector can be attached to the lift truck connector without pulling during lifting and lowering operations. DO NOT damage the battery cables during installation. Install the battery.

6. Replace buckle and strap and tighten to prevent the battery from moving.

WARNING To prevent injury, equipment damage, and unexpected battery movement, the battery must be level when it is moving. Make sure the battery stand is level, correctly aligned with the battery, and adjusted as described in the following procedure.

1. Move the lift truck to a safe, level area.

2. Turn the key switch to the OFF position and disconnect the battery connector.

3. Align the battery stand and puller with the battery compartment and battery.

4. Adjust the legs of the battery stand so top of rollers are the same height as the bottom of the battery. Make sure the battery stand is level.

WARNING

7. Remove the blocks from under the truck.

To prevent personal injury and equipment damage, DO NOT permit hook to touch battery cell terminals.

8. Connect the battery. Test the operation of the motorized hand truck before returning the truck to service.

5. Attach the hook of the battery puller to the lifting hole of the battery. DO NOT touch battery cell terminals with the hook.

16

8000 SRM 1666 6. Remove the side gate.

7. Stand on base of the battery puller, release the ratchet lever, and operate the crank to pull the battery onto the battery stand.

Install 1. Remove the side gate and install the battery puller on lift truck at center of the battery compartment opening on the opposite side of lift truck from the battery stand.

Battery Maintenance 2. Attach hook of the battery puller to the lifting hole of battery. DO NOT touch battery cell terminals with the hook.

3. Stand on the base of the battery puller, release the ratchet lever, and operate the crank to pull the battery onto the battery stand.

4. Install the side gates and remove the battery puller from frame.

5. Connect the battery.

WARNING To prevent personal injury and equipment damage, DO NOT permit hook to touch battery cell terminals.

17

NOTES

18

TECHNICAL PUBLICATIONS 8000 SRM 1666

3/15 (12/13)

CAPACITIES AND SPECIFICATIONS P2.0 [A290]; W45ZHD [A419]

PART NO. 4035868

8000 SRM 1511

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR •

• • • • • • • • • • • • • •

The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the product. Updated technical service information may be available from your local authorized Hyster® dealer. Service Manuals provide general guidelines for maintenance and service and are intended for use by trained and experienced technicians. Failure to properly maintain equipment or to follow instructions contained in the Service Manual could result in damage to the products, personal injury, property damage or death.

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 when making 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.

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury and property damage.

On the lift truck, the WARNING symbol and word are on orange background. The CAUTION symbol and word are on yellow background.

Capacities and Specifications

Table of Contents

TABLE OF CONTENTS Hydraulic System .................................................................................................................................................... 1 Hydraulic Oils ..........................................................................................................................................................1 Grease ...................................................................................................................................................................... 1 Truck Weights ......................................................................................................................................................... 2 Tires ......................................................................................................................................................................... 2 Torque Specifications .............................................................................................................................................. 2 Caster Assembly ..................................................................................................................................................2 Caster Assembly (Dynamic) ............................................................................................................................... 2 Master Drive Unit ...............................................................................................................................................2 Steering ............................................................................................................................................................... 2 Electrical ..............................................................................................................................................................2 Lift Mechanism ................................................................................................................................................... 3 Covers .................................................................................................................................................................. 3 Operator Guard ...................................................................................................................................................3 Battery Specifications ............................................................................................................................................. 4 This section is for the following models: P2.0 [A290]; (W45ZHD) [A419]

©2013 HYSTER COMPANY

i

"THE QUALITY KEEPERS" HYSTER APPROVED PARTS

8000 SRM 1511

Hydraulic System

Hydraulic System Unit

Volts

Operating Pressure1 No Load

24 P2.0 and W45ZHD

Ampere Draw2

Lift Time (sec)

Relief Setting

Lower Time (sec)

No Rated Pressure Amp No Rated No Rated 3 Load Load Draw Load Load Load Load

Rated Load

2.07 14.82 MPa MPa (2150 psi) (300 psi)

37

100

24.1 MPa (3500 psi)

150

2.3

3.1

2.8

1.4

Standard Specifications Hydraulic Tank Capacity - 1.0 liter (1.06 qt) Pump Displacement (24 Volts) 1.25 cm3/rev (0.076 in.3/rev) Creep Rate - 6.4 mm (0.25 in.) Maximum In 10 Minutes @ 32°C (90°F) Oil Temperature Footnotes 1 ±0.35 MPa (±51 psi) @ 21°C (70°F) Oil Temperature 2 ±10 Amps @ 1.270 Battery Specific Gravity 3+0.6 to 0.0 MPa (+87 to 0 psi) @ 32°C (90°F) Oil Temperature Full Flow

Hydraulic Oils Operating Condition

Standard

CS/Freezer

Truck Temperature Range

0 to −84°C (32 to −120°F)

−18 to −84°C (0 to −120°F)

For All Hydraulically Actuated Equipment Specification

ISO VG 46 Antiwear (HCE-140)

Exxon Univis® HVI 26

Pour Point Maximum

−15°C (5.0°F)

−60°C (−76.0°F)

Field Personnel Note: The product listed above is the approved source that meets or exceeds Hyster specifications.

The use of products other than that listed above is unauthorized.

Grease Fittings and Bearings Application

Standard/CS/Freezer

Steer Bearings

Approved Vendor

Mobilgrease® 28

Amsoil GHD®

Oil

Synthetic

Synthetic

Thickener

Clay

Lithium Complex

Grade NGLI

1.5

2.0

Moly-Fortified

No

Yes

Dropping Pt.

310°C (590°F)

288°C (550°F)

Field Personnel Note: The product listed above is the approved source that meets or exceeds Hyster specifications.

The use of products other than that listed above is unauthorized.

1

Tires

8000 SRM 1511

Truck Weights Unit

Fork Length 900 mm (35.4 in.)

Weight

Fork Length 1000 mm (39.4 in.)

Weight

Fork Length 1150 mm (45.2 in.)

Weight

P2.0 and W45ZHD

518 kg (1142 lb)

523 kg (1153 lb)

530 kg (1168 lb)

Tires Unit

Size

Item

Torque

P2.0

230 mm × 84 mm

Wheel Lug Nut

120 N•m (88 lbf ft)

W45ZHD

254mm x 102mm

Wheel Lug Nut

120 N•m (88 lbf ft)

Torque Specifications CASTER ASSEMBLY Caster Mounting Capscrews (4 each) 57 N•m (42 lbf ft) Caster Axle Capscrews (2 each) 35 N•m (25 lbf ft)

Steering Bearing to MDU Casting (8) 23 N•m (17 lbf ft) Drive Unit to Steering Bearing (8) 23 N•m (17 lbf ft)

STEERING

Caster Pivot Bolt (1 each) 85 N•m (63 lbf ft)

Steer Bracket to MDU (4) 19.2 N•m (15 lbf ft)

CASTER ASSEMBLY (DYNAMIC)

Steer Handle to Tiller Bracket (2) 27 N•m (20 lbf ft)

Caster Mounting Capscrews (4 each) 38 N•m (28 lbf ft) Caster Axle Capscrew (1 each) 220 N•m (162 lbf ft) Caster Support to Frame (2 each) 38 N•m (28 lbf ft) Caster Shock Absorber Assembly Mounting Capscrews (2 each) 88 N•m (65 lbf ft)

Butterfly Throttle Control to Handle (2) 1 N•m (9 lbf in) Return Spring Mounting Stud (1) 35 N•m (26 lbf ft) Return Spring to Support Bracket (1) 35 N•m (26 lbf ft) Control Arm Pivot Pin to Support Bracket (1) 35 N•m (26 lbf ft)

MASTER DRIVE UNIT

ELECTRICAL

Motor Mounting Capscrews (4) 17 N•m (13 lbf ft)

Brake Assembly to Traction Motor Capscrews (3) 10 N•m (89 lbf in)

Transmission to Frame Mounting Bolts (4) 225 N•m (165 lbf ft) Drive Tire Wheel Lug Nuts (5) 120 N•m (88 lbf ft)

2

Traction Motor Power Wire Nuts (3) 8 N•m (71 lbf in)

8000 SRM 1511

Torque Specifications

Contactor to Control Panel (2) 4 N•m (35 lbf in)

Pull Rod Pivot Shaft to Rocker Assembly (2) 35 N•m (26 lbf ft)

Contactor Wire Nuts (2) 8 N•m (71 lbf in)

Rear Fork Pivot Shaft to Fork (2) 35 N•m (26 lbf ft)

Controller to Control Panel Nuts (4) 14 N•m (124 lbf in)

Hydraulic Cylinder Gland Nut (1) 275 N•m (203 lbf ft)

Power Wires to Controller Capscrews (5) 14 N•m (124 lbf in)

COVERS

Horn to Control Panel (2) 35 N•m (26 lbf ft) Control Panel to Frame (5) 35 N•m (26 lbf ft) Emergency Stop and Ignition Bracket to Frame (4) 25 N•m ( lbf ft) Battery Retainer Capscrew (1) 35 N•m (26 lbf ft)

LIFT MECHANISM

Battery Tray Mounting Capscrews (4) 35 N•m (26 lbf ft) Battery Retainer Capscrew (1) 35 N•m (26 lbf ft) Center Top Cover Capscrew (1) 35 N•m (26 lbf ft) Center Main Cover Mounting Nuts (3) 35 N•m (26 lbf ft) Main Cover Mounting Nuts (2) 35 N•m (26 lbf ft)

OPERATOR GUARD

Hydraulic Power Unit Mounting Capscrews (2) 35 N•m (26 lbf ft)

Guard Assembly to Frame Capscrews (6) 25.6 N•m (19 lbf ft)

Drive Frame Pivot Shaft to Master Drive Unit Assembly (2) 35 N•m (26 lbf ft)

Wire Retention Clamp to Guard Assembly Capscrew (1) 52 N•m (38 lbf ft)

Front Fork Frame Pivot Shaft to Fork (2) 35 N•m (26 lbf ft)

3

Battery Specifications

8000 SRM 1511

Battery Specifications Battery Compartment is shown in Figure 1.

Figure 1. Battery Compartment Table 1. Battery Specifications P2.0 Voltage

Ampere Hours (Max)

Kilowatt Hours (Max)

Compartment Length (X)

Compartment Width (Y) (Max)

Recommended Height (Max)

Weight (Max)

24

220

5.28

704 mm (27.7 in.)

223 mm (8.78 in.)

627 mm (24.7 in.)

212 kg (467 lb)

Table 2. Battery Specifications W45ZHD

4

Voltage

Ampere Hours (Max)

Kilowatt Hours (Max)

24

110

4.58

Compartment Compartment Recommended Length (X) Width (Y) (Max) Height (Max) 704 mm (27.7 in.)

153 mm (6.02 in.)

655 mm (25.8 in.)

Weight (Max) OPEN

TECHNICAL PUBLICATIONS 8000 SRM 1511

12/13 (6/11)

STEERING MECHANISM P2.0 [A290]; W45ZHD [A419]

PART NO. 4035861

1600 SRM 1504

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR •

• • • • • • • • • • • • • •

The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the product. Updated technical service information may be available from your local authorized Hyster® dealer. Service Manuals provide general guidelines for maintenance and service and are intended for use by trained and experienced technicians. Failure to properly maintain equipment or to follow instructions contained in the Service Manual could result in damage to the products, personal injury, property damage or death.

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 when making 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.

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury and property damage.

On the lift truck, the WARNING symbol and word are on orange background. The CAUTION symbol and word are on yellow background.

Table of Contents

TABLE OF CONTENTS General .....................................................................................................................................................................1 Special Precautions ................................................................................................................................................. 1 Control Handle Head .............................................................................................................................................. 2 Control Handle ........................................................................................................................................................ 3 Remove ................................................................................................................................................................ 3 Install ...................................................................................................................................................................3 Gas Spring ............................................................................................................................................................... 6 Discharging the Gas Spring ............................................................................................................................... 6 Remove ................................................................................................................................................................ 6 Install ...................................................................................................................................................................7 Troubleshooting .......................................................................................................................................................7 This section is for the following models: P2.0 [A290]; (W45ZHD) [A419]

©2015 HYSTER COMPANY

i

"THE QUALITY KEEPERS" HYSTER APPROVED PARTS

1600 SRM 1504

General

General The control handle assembly is designed to perform several functions. The standard control handle includes the speed/direction control and buttons for the horn, traction reversing, and hydraulic functions. The control handle is connected to the Master Drive Unit (MDU) and is used to steer the truck as it turns the MDU. Move the control handle

left or right to turn the drive/steer tire and steer the truck. Controls mounted in the handle are linked to the control panel by a wiring harness that passes through the center of the handle. The brake is applied when the handle is in the full up or down position.

Special Precautions WARNING The capacitor in the controller can hold an electrical charge after the battery is disconnected. To prevent electrical shock and personal injury, discharge the capacitor before inspecting or repairing any component. Wear safety glasses. Make certain the battery has been disconnected. DO NOT use a screwdriver to discharge the traction motor controller.

WARNING To avoid personal injury and prevent electrical shock, perform the following steps before performing any troubleshooting or adjustments, and connecting or disconnecting a handset or PC.

CAUTION To avoid controller damage, always disconnect the battery. Discharge the capacitor and never put power to the controller with any power wire disconnected.

Never short any controller terminal or motor terminal to battery. Make sure to use proper procedures when servicing the controller.

1. Move the truck to a safe, level area. Turn the key switch to the OFF position and disconnect the battery.

2. Remove the drive unit compartment cover to access the drive unit compartment.

CAUTION DO NOT short across the motor controller terminals with a screwdriver or jumper wire.

3. Discharge the capacitors in the controllers by connecting a 200-ohm, 2-watt resistor across the controller's B+ and B− terminals using insulated jumper wires. See Figure 1.

4. Remove the 200-ohm, 2-watt resistor before reconnecting the battery.

1

Special Precautions

1600 SRM 1504 Legend for Figure 1 1.

2.

3.

4.

5.

CONTROLLER POSITIVE CONNECTION INSULATED JUMPER WIRES 200-OHM, 2-WATT RESISTOR NEGATIVE CONNECTION

Figure 1. Discharging Controller

Control Handle Head Refer to the section Electrical System 2200SRM1508 for instructions on removing and installing the control handle head from the control

2

handle. The instructions for disassembly and assembly of the control handle head can be located in the same section.

1600 SRM 1504

Control Handle

Control Handle REMOVE WARNING The gas springs used on the control handle are installed under tension and can release with enough force to cause personal injury or property damage.

WARNING The capacitor in the controller can hold an electrical charge after the battery is disconnected. To prevent electrical shock and personal injury, discharge the capacitor before inspecting or repairing any component in the drive unit compartment.

Wear safety glasses. Make certain the battery has been disconnected. Refer to the Special Precautions section of this manual.

1. Move the lift truck to a safe, level area and block the wheels to prevent movement.

8. Remove the capscrew securing the pivot shaft to the support bracket and remove the pivot shaft.

9. Remove the control arm from the support bracket.

10. Remove the retaining nuts securing the prox sensor to the control handle arm and remove the prox sensor.

11. If bushings are worn, remove the bushings from the control handle arm.

INSTALL 1. If previously removed, install the bushings into the control handle arm.

2. Install the new gas spring into the control handle arm. Refer to Gas Spring in the section.

2. Turn the key switch to the OFF position and disconnect the battery.

3. Install the prox sensor onto the control handle arm and secure with the retaining nuts. Leave retaining nuts loose until the control handle arm is installed.

3. Remove the drive unit compartment cover. Refer to AC Motor Repair 0620SRM1513.

4. If removed, install the control handle head. See the section Electrical System 2200SRM1508.

4. Discharge the capacitor in the controller by connecting a 200-ohm, 2 watt resistor between the B+ and B- connectors on the controller. See Figure 1.

5. Position the control handle arm onto the support bracket and install the pivot shaft.

5. Disconnect the control handle wiring harness plug and the control handle arm prox sensor plug located on top of the drive motor.

For the following instructions refer to Figure 2 or Figure 3.

6. If necessary, remove the control handle head.

See the section Electrical System 2200SRM1508.

CAUTION Discharging the gas spring is a destructive operation.

6. Install the capscrew as removed. Torque to 35 N•m (26 lbf ft).

7. Secure the lower end of the gas spring to the support bracket with the capscrew and nut as removed.

8. Adjust the prox sensor so the end of the sensor is no more than 4 mm (0.16 in.) from the support bracket. Tighten the retaining nuts.

9. Reconnect the control handle wiring harness and prox sensor.

10. Install the drive unit compartment cover.

11. Connect the battery and test the operation of the lift truck prior to returning to service.

7. Discharge and remove the gas spring. Refer to Gas Spring in this section.

3

Control Handle

1.

2.

3.

4.

5.

6.

7.

8.

1600 SRM 1504

CONTROL HANDLE HEAD CAPSCREW LOCKNUT LOCKNUT HOLE PLUG GAS SPRING SCREW CAPSCREW

9.

10.

11.

12.

13.

14.

15.

16.

CAPSCREW PIVOT SHAFT STRAP CLAMP BUSHING SENSOR BALL STUD CONTROL HANDLE ARM RETAINING NUT

Figure 2. Control Handle Assembly (P2.0 (A290))

4

1600 SRM 1504

Control Handle Legend for Figure 3 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

CONTROL HANDLE HEAD CAPSCREW LOCKNUT HOLE PLUG GAS SPRING PIVOT SHAFT STRAP CLAMP BUSHING SENSOR BALL STUD CONTROL HANDLE ARM RETAINING NUT

Figure 3. Control Handle Assembly (W45ZHD (A419)

5

Gas Spring

1600 SRM 1504

Gas Spring WARNING Disconnect the battery by separating the battery connector before opening the compartment cover and before inspecting or repairing the electrical system. DO NOT place tool on top of the battery. If a tool causes a short circuit, the high-current flow from the battery can cause personal injury or property damage.

WARNING The capacitor in the traction motor controller can hold an electrical charge after the battery is disconnected. To prevent electrical shock and personal injury, discharge the capacitor before inspecting or repairing any component. Make certain the battery has been disconnected and always wear safety glasses. See Special Precautions in this section. DO NOT attempt to discharge the capacitors by shorting the controller.

WARNING

NOTE: This process is a destructive operation to the gas spring. A new gas spring must be used during reassembly. This is necessary because internal damage to the spring components which are not detectable could cause damage or injury when the spring is removed.

1. Check that the handle return spring is installed and properly secure the control handle arm in the full upright position. Remove the plastic plugs to increase visibility of the gas spring.

WARNING Contents are under pressure. This process may eject metal chips and oil.

2. Locate the gas spring inside the control handle through the access hole on the front of the control handle and drill a 3 mm (0.125 in.) hole into the gas spring cylinder shell to relieve pressure.

3. Clean up any discharged oil and dispose of in accordance with local regulations.

The gas spring used on the control handle is installed under tension and can release with enough force to cause personal injury or property damage.

To remove the gas spring from the control handle:

Review the following procedures before removing the gas spring.

1. Remove the plastic plugs to access the gas spring.

DISCHARGING THE GAS SPRING WARNING Goggles and a face shield must be worn for personal protection as metal chips and hydraulic lubricant may be ejected from the drill operation due to the high internal pressure.

CAUTION The control handle return spring is charged with pressurized gas and contains a hydraulic oil lubricant.

REMOVE

CAUTION DO NOT damage the control handle wiring harness inside the control handle arm.

2. Discharge the pressure from the gas spring. See Discharging the Gas Spring.

3. Remove the retention clip from the gas spring ball socket. Disconnect the gas spring from the ball stud.

4. Remove the ball stud from inside the control arm as necessary.

5. Remove the capscrew and locknut securing the rod end of the gas spring to the tiller swivel.

6

1600 SRM 1504

Gas Spring

INSTALL 1. Install ball stud and nut into control arm if removed. Tighten to 35 N•m (26 lbf ft).

2. Lubricate both connection points with multipurpose lithium complex grease with 2 to 4% molybdenum.

CAUTION DO NOT damage the control handle wiring harness inside the control handle arm.

3. Make certain the control handle arm is secured in the full upright position and position the new gas spring into the control handle arm. Connect the upper end of the gas spring to the ball stud inside the control handle arm. Install the retention clip to the gas spring ball socket as removed.

NOTE: Apply Loctite® 242 to the capscrew threads before installing the nut.

4. Align the lower end of the gas spring into position using a screwdriver and hold in position.

Install the capscrew and locknut securing the rod end of the gas spring to the steer swivel.

Tighten to 35 N•m (26 lbf ft).

5. Install the plastic plugs to the access holes on the control handle shaft as removed.

6. Test for proper operation. Install covers as removed.

Troubleshooting PROBLEM Steering is rough or difficult.

Steering handle does not return to the vertical position.

POSSIBLE CAUSE

PROCEDURE OR ACTION

Damaged, worn, or defective steering handle swivel bearing(s).

Replace bearings.

Steering handle swivel bearing(s) need lubrication.

Lubricate or repack bearings.

Bearing retaining nut torque incorrect.

Loosen retaining nut and tighten to correct torque. See the section Master Drive Unit 0630SRM1503.

Drive unit housing (steer) damaged.

Replace drive unit housing bearing (steer).

bearing

Gas spring is weak or broken.

Replace gas spring.

Gas spring ball stud broken or loose.

Retighten or replace gas spring ball stud.

7

NOTES

8

TECHNICAL PUBLICATIONS 1600 SRM 1504

3/15 (12/13)(6/11)