Hyster H160 Service Manual - PDF DOWNLOAD

SX/SR TRANSISTOR MOTOR CONTROLLERS AND HANDSET ALL ELECTRIC LIFT TRUCKS THAT HAVE A SX OR SR TRANSISTOR MOTOR CONTROLLER

PART NO. 1454588

2200 SRM 697

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR • When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks.

• Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit 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!

SX/SR Transistor Motor Controllers and Handset

Table of Contents

TABLE OF CONTENTS Introduction to SEM ..........................................................................................................................................

Advantages of Transistorized SEM ..............................................................................................................

Features of SEM ............................................................................................................................................

Solid-State Reversing................................................................................................................................

Performance and Efficiency ......................................................................................................................

Field Weakening........................................................................................................................................

Regenerative Braking ...............................................................................................................................

SX Transistor Motor Controllers.......................................................................................................................

Introduction ...................................................................................................................................................

Proportional Operation for Dual-Motor Trucks ...........................................................................................

General.......................................................................................................................................................

Operation ...................................................................................................................................................

Controller Features .......................................................................................................................................

General.......................................................................................................................................................

Creep Speed ...............................................................................................................................................

Controlled Acceleration.............................................................................................................................

Current Limit ............................................................................................................................................

Braking...........................................................................................................................................................

Regenerative Braking to Zero Speed........................................................................................................

Pedal Position Braking .............................................................................................................................

Auto Braking .............................................................................................................................................

Conventional Plug Braking ......................................................................................................................

Auxiliary Speed Control ................................................................................................................................

Field Weakening........................................................................................................................................

Speed Limits ..............................................................................................................................................

Ramp Operation.............................................................................................................................................

Ramp Start ................................................................................................................................................

Antirollback ...............................................................................................................................................

Steer Pump Contactor Time Delay ...............................................................................................................

On-Board Coil Drivers and Internal Coil Suppression................................................................................

System Protective Override ..........................................................................................................................

SRO (Static Return to Off) ........................................................................................................................

Accelerator Volts Hold Off.........................................................................................................................

Pulse Monitor Trip (PMT).........................................................................................................................

Thermal Protector (TP) .............................................................................................................................

Low Voltage................................................................................................................................................

SR Lift Pump Controllers ..................................................................................................................................

Sensor Interface/Contactor Driver Module ......................................................................................................

Diagnostic Status Codes and Troubleshooting .................................................................................................

General Maintenance Instructions...............................................................................................................

Special Precautions ...................................................................................................................................

Diagnostics .....................................................................................................................................................

Systems Diagnostics..................................................................................................................................

Status Codes ..................................................................................................................................................

Standard Status Codes .............................................................................................................................

Stored Status Codes ..................................................................................................................................

Other Features...............................................................................................................................................

Hourmeter Readings .................................................................................................................................

Maintenance Alert and Speed Limit ........................................................................................................

Battery Discharge Indication (BDI) .........................................................................................................

Internal Resistance Compensation ..........................................................................................................

©2003 HYSTER COMPANY

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Table of Contents

SX/SR Transistor Motor Controllers and Handset

TABLE OF CONTENTS (Continued) Handset Programmable ............................................................................................................................

RS 232 Communication Ports...................................................................................................................

Circuit Board Coil Driver Modules...........................................................................................................

Maintenance Management Capability .....................................................................................................

Interactive Instrument Panel Modes .......................................................................................................

General Troubleshooting Instructions..........................................................................................................

Status Code Troubleshooting Tables.................................................................................................................

SX/SR Handset Instructions .............................................................................................................................

General Features ...........................................................................................................................................

Connecting the Handset................................................................................................................................

Startup Sequence...........................................................................................................................................

Setup Mode ....................................................................................................................................................

Stored Status Code Mode ..............................................................................................................................

Clearing the Stored Status Codes.................................................................................................................

Restarting Lift Truck.....................................................................................................................................

SX Traction Controller Function Descriptions .................................................................................................

Premium Instrument Panel Interactive Modes ...........................................................................................

SR Pump Controller Function Descriptions .....................................................................................................

Premium Instrument Panel Interactive Modes ...........................................................................................

This section is for the following models: All Electric Lift Trucks That Have a SX or SR Transistor Motor Controller

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16 16 17 17 17 19 21 59 59 61 61 62 63 63 63 64 71 74 77

2200 SRM 697

Introduction to SEM

Introduction to SEM ADVANTAGES OF TRANSISTORIZED SEM Historically, most electric lift trucks have relied on series motor designs because of their ability to produce very high levels of torque at low speeds. See Figure 1. As the demand for high-efficiency systems increases, shunt motors are now often being considered over series motors. In most applications, by independently controlling the field and armature currents in the separately excited motor, the best attributes of both the series- and the shunt-wound motors can be combined.

In a shunt motor, the variation of speed from no load to normal full load on level ground is less than 10 percent. For this reason, shunt motors are considered to be constant speed motors. See Figure 2.

Figure 2. Shunt Motor

Figure 1. Series Motor In a shunt motor, the field is connected directly across the voltage source and is therefore independent of variations in load and armature current. If field strength is held constant, the torque developed will vary directly with the armature current. If the mechanical load on the motor increases, the motor slows down, reducing the back EMF (which depends on the speed, as well as the constant field strength).

The reduced back EMF allows the armature current to increase, providing the greater torque needed to drive the increased mechanical load. If the mechanical load is decreased, the process reverses.

The motor speed and the back EMF increase, while the armature current and the torque developed decrease. Thus, whenever the load changes, the speed changes also, until the motor is again in electrical balance.

In the separately excited motor, the motor is operated as a fixed field shunt motor in the normal running range. When additional torque is required (climbing a ramp, etc.) the field current is increased to provide the higher level of torque. In most cases, the performance can be very similar to that of a comparable size series motor. See Figure 3.

Figure 3. Separately Excited Motor

1

Introduction to SEM

FEATURES OF SEM Solid-State Reversing The direction of armature rotation on a shunt motor is determined by the direction in which current flows through the field windings. Because the shunt motor field only typically requires about 10 percent of the armature current at full torque, it is normally cost effective to replace the double pole, double throw reversing contactor with a low-power transistor H-Bridge circuit. See Figure 4.

Figure 4. Simplified Motor Circuit By energizing the transistors in pairs, current can be made to flow in either direction in the field. The field and armature control circuits typically operate at 12kHz to 15kHz, a frequency range normally above human hearing. This high frequency, coupled with the elimination of directional contactors, provides very quiet lift truck operation.

The line contactor is normally the only contactor required for the SEM traction circuit. This contactor is used for both precharge of the line capacitors and for shutdown of the motor circuit in the event of certain malfunctions. The line contactor is energized and de-energized by the key switch.

Performance and Efficiency Because the SEM controller has the ability to control both the armature and field circuits independently,

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2200 SRM 697 the system can normally be adjusted for maximum system efficiencies at certain operating parameters.

Generally speaking, with the ability of independent field and armature control, the motor performance curve can be maximized through proper control application.

Field Weakening Field weakening of a series-wound motor is accomplished by placing a resistor in parallel with the field windings of the motor. Bypassing some of the field current into the resistor causes the field current to be less or weakened, and motor speed can increase.

To change the speed during field weakening, it is necessary to change the resistor value. In a separately excited motor, independent control of the field current provides for an infinite adjustment of field-weakened speeds, between motor base speed and maximum weak field. The transistorized control also eliminates the contactor and resistor required for field weakening with a series motor.

With a separately excited motor, overhauling speed limit, or downhill speed, will also be more constant.

By its nature, the SEM will try to maintain a constant speed downhill. This characteristic can be enhanced by increasing the field strength with the control. Overhauling load control works in just the opposite way of field weakening: Armature rotation slows with the increase of current in the field.

Regenerative Braking Regenerative braking (braking energy returned to the battery) may be accomplished completely with solid-state technology. The main advantage of regenerative braking is increased motor life. Motor current is reduced by 50 percent or more during braking while maintaining the same braking torque as electrical braking with a diode clamp around the armature. The lower current translates into longer brush life and reduced motor heating. Solid-state regenerative braking also eliminates a power diode, current sensor, and contactor from the circuit.

2200 SRM 697

SX Transistor Motor Controllers

SX Transistor Motor Controllers INTRODUCTION The SX controllers are sealed units with no serviceable components. User-adjustable features allow the controllers to be customized for different applications. Self-diagnostics are provided to monitor internal components as well as to detect problems with certain inputs and outputs. Adjustable parameters and status codes are accessed using a handset or a personal computer. See the section Troubleshooting and Adjustments With a Computer 2200 SRM 597 for information on the use of a PC. Handset and SX/SR cable ........ Hyster P/N 1361415 SX/SR cable* only .................... Hyster P/N 1361414 (*For connecting LX/ZX handset to SX/SR controller) PC adapter cable kit*............... Hyster P/N 1361412

inside motor and letting the wheel roll at whatever speed is dictated by the outside wheel. The main disadvantage of this system is that no torque is available from the inside motor at this time and performance in a turn is reduced. On a dual-motor truck, when the steer wheel nears the 90-degree turn angle, the inside motor is reconnected in the opposite direction of the outside wheel. At this point, torque is returned to the inside wheel, and the speed is the same on both motors.

With two controllers, the speed of each motor can be regulated independently. The driver controls the speed of the outside wheel with the accelerator input signal. The inside wheel speed is controlled by the turn angle of the steer tire. A potentiometer attached to the steer axle communicates the steer angle to the controllers. See Figure 5.

(*Includes PC cable, 9-pin to 20-pin adapter and cord) The SX controller is a transistorized separately excited motor (SEM) traction motor controller, providing separate control of the motor field and armature currents. The SX 450 traction controller is rated at 400 amps armature current and 40 amps field current. Two SX controllers are utilized on dual-drive motor trucks to provide proportional control of drive motor speeds during turns. The left control is considered the primary control and the right control is the secondary control.

PROPORTIONAL OPERATION FOR DUAL-MOTOR TRUCKS General A key performance advantage of this controller is the ability to achieve actual proportioning of motor speed on dual-motor trucks. When the lift truck turns, the outside drive wheel turns in a larger circle than the inside wheel. In a nonproportioning, or single-control system, at some degree of turn angle, the inside wheel must slow down to prevent scrubbing of the wheel. This is accomplished on a dual-motor, single-control system by disconnecting the power to the

Figure 5. Steer Angle/Drive Motor Performance Profile See the section Electrical System 2200 SRM 698 for troubleshooting, installation, and adjustment procedures for the steer angle potentiometer.

Refer to Table 1 for the SX traction controller connections.

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SX Transistor Motor Controllers

2200 SRM 697

Table 1. SX Traction Controller Connections/Descriptions Pin No.

P P L U G

4

Left Traction Controller

Right Traction Controller

Wire No.

Description

Wire No.

P1

12

Battery Volts From Positive (BAT) Side of Key Switch

12

P2

10

Battery Volts From Negative (IGN) Side of Key Switch

10

P3

15

Battery Volts From Start Switch

15

P4

6

Battery Volts From Forward Switch

6

P5

8

Battery Volts From Reverse Switch

8

P6

7

Battery Volts From Seat Switch

7

P7

29

Accelerator Potentiometer Wiper Voltage Signal Input

29

P8

13

Controller Negative (To Steer Angle Pot)

Not Used

-

P9

67

+5 Volt Output (To Steer Angle Pot)

Not Used

-

P10

50

+12 Volt Enable Signal Output (To Lift Pump Controller)

PMT Enable Input (From Left Traction Controller)

51

P11

75

+12 Volt Plug/Regen Output (12 Volt + Plug)

Not Used

-

P12

66

P13

-

Not Used

Not Used

-

P14

110

Brush Wear Indicator Input (From Lift Pump Controller or SICDM)

Not Used

-

P15

121

I MOTOR OUT

I MOTOR OUT

120

P16

120

Motor Current Compensation

Motor Current Compensation

121

P17

24

Line Contactor Coil Driver

Not Used

-

P18

-

Not Used

Power Steering Contactor Coil Driver

60

P19

111

+5 Volt Power Supply Output (To Sensor Interface/Contactor Driver Module)

+5 Volt Power Supply Output (To Instrument Panel)

RED-1

P20

109

Motor Overtemperature Input (From Lift Pump Controller or SICDM)

P21

51

P22

GRN-1

Serial Receive - Connects to Instrument Panel

GRN-3

P23

WHT-1

Serial Transmit - Connects to Instrument Panel

WHT-3

Steer Angle Potentiometer Wiper Voltage Signal Input

PMT Enable Output

Not Used

66

109 -

2200 SRM 697

SX Transistor Motor Controllers

Table 1. SX Traction Controller Connections/Descriptions (Continued)

Pin No.

Left Traction Controller

Right Traction Controller

Wire No.

Description

Wire No.

PY1

-

Clock (Out)

-

PY2

-

Data (Out)

-

PY3

-

Enable (Out)

-

PY4

-

Negative

-

PY

PY5

-

+5 Volt Supply

-

P L U G

PY6

-

Cont/Store (In) (Handset)

-

PY7

-

External Jumper to PY12

-

PY8

-

Value

-

PY9

-

Function

-

PY10

-

External Jumper to PY11

-

PY11

-

Serial Receive/Internal connection to P22

-

PY12

-

Serial Transmit/Internal connection to P23

-

Refer to Figure 6 for a typical SX traction controller schematic. See the section Wiring Diagrams 8000 SRM 696 for specific wiring details for your lift truck.

motor is stopped to change direction, torque is always present on the inside wheel, providing a smoother ride throughout the turning radius of the lift truck.

Operation

NOTE: Left and right traction controllers are physically identical. Function 17, Controller Type, is used to identify a controller as a right controller or a left controller.

When the steer tire angle reaches approximately 25 degrees, the speed of the inside wheel decreases proportionally to the speed of the outside wheel. This proportional decline will continue on a linear path until the steer tire angle is approximately 65 degrees.

At this point, the inside wheel will stop. As the steer angle is increased toward the 90-degree point, the inside wheel will reverse direction and start to accelerate proportionally in speed. As the steer angle reaches the 90-degree point, the inside wheel speed will be the same as that of the outside wheel. During this entire turn, except for several degrees when the

NOTE: Traction motor controller Functions 1 through 14, Function 16, and Functions 18 through 63 must have identical values programmed for the right traction controller and the left traction controller. Never change the value of one of these functions on one traction controller without changing the value of the same function on the opposite controller.

5

SX Transistor Motor Controllers

Figure 6. Typical SX Traction Controller Schematic

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2200 SRM 697

2200 SRM 697

CONTROLLER FEATURES General The controller has an on-time range of approximately 0 to 100 percent. The SX and SR controllers operate at a constant frequency, and the percent on time is controlled by the pulse width of the voltage/current applied to the motor circuits.

Creep Speed With the accelerator at maximum volts (approximately 4.2 to 3.5 volts), creep speed can be adjusted

by Function 2. At creep speed, the ON time can decrease to approximately 5 percent, with the OFF time at approximately 95 percent. At full transistor operation, this condition will be reversed (short OFF time, long ON time). This variation of ON and OFF time of the oscillator varies the voltage applied to the motor, thereby varying the speed of the motor for a given load.

SX Transistor Motor Controllers deceleration. If the lift truck is moving, and the directional lever is moved from one direction to the other, the regenerative braking signal is initiated.

Once the regenerative braking signal has been initiated, the field current is increased. Armature current is regulated to the regenerative braking current limit as set by Function 9. As the lift truck slows down, the field current continues to increase, and transistor Q5 begins to turn on and off. See Figure 7.

The field current will increase until it reaches a preset value set by Function 10, and transistor Q5 ON time will increase until it reaches 100 percent ON time. Once both of the above conditions have been met, and the regenerative braking current limit can no longer be maintained, the braking function is canceled. The fields will then reverse, and the controller reverts back to motoring.

Controlled Acceleration This feature allows for adjustment of the time it takes for the controller to accelerate to 100 percent applied battery voltage to the motor on hard acceleration. Controlled acceleration is adjustable from 0.1 to 22 seconds. Controlled acceleration is adjusted using Function 3 (standard instrument panel) or Functions 48, 52, 56, and 60 (premium instrument panel).

Current Limit This circuit monitors motor current by utilizing sensors in series with the armature and field windings.

The information is used to maintain maximum currents at a preset value. If heavy load currents are detected, this circuit overrides the oscillator and limits the average current to a value set by Function 4 and Function 8. The C/L setting is based on the maximum thermal rating of the controller. Because of the flyback current, the motor current is usually greater than battery current, except at 100 percent ON time.

BRAKING

Figure 7. Regenerative Braking Circuit Part of the energy produced by the motor during regenerative braking is returned to the battery, and part is converted to heat in the drive motor.

Function 9, Regen Current Limit, is user adjustable and will alter the distance the lift truck requires to reach zero speed. Function 10, Regen Field Current, is not normally adjusted in the field.

Regenerative Braking to Zero Speed Slowdown is accomplished when reversing direction by providing a small amount of retarding torque for

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SX Transistor Motor Controllers

2200 SRM 697

Pedal Position Braking

AUXILIARY SPEED CONTROL

This feature allows control of the reversing distance based on pedal position when there has been a directional switch change. Pedal position will reduce the regenerative braking or plugging current to the value set by this function as the accelerator is returned to the creep speed position. Maximum current is obtained with the accelerator in the top speed position.

This feature is adjustable by using Function 16 on the handset.

Field Weakening

Auto Braking

NOTE: The minimum field current has been determined by the factory. Function 7 is not normally adjusted in the field.

This feature is enabled by initiating a neutral position using either the directional switch or the accelerator switch. Once activated, Auto Braking operates similar to pedal position braking and is adjusted by Function 21.

Conventional Plug Braking Plug braking only occurs when the steer tire is at an angle of 65 degrees or greater. At steer angles less than 65 degrees, the truck is slowed by regenerative braking to zero speed.

During plug braking (when reversing direction), slowdown is accomplished by providing a small amount of retarding torque for deceleration. If the lift truck is moving, the steer tire is at an angle of 65 degrees or greater, and the directional lever is moved from one direction to the other, the plug signal is initiated. Once the plug signal has been initiated, the field is reversed, and the armature current is regulated to the plug current limit as set by Function 5. Armature current is regulated by increasing the field current as the lift truck slows down. Once the field current reaches a preset value, set by Function 10, and armature plug current can no longer be maintained, the braking function is canceled, and the controller reverts back to motoring.

All energy produced by the motor during plugging is converted to heat in the drive motor.

Function 5, Plugging Current Limit, is user adjustable and will alter the plugging distance. Function 10, Regen Field Current, is not normally adjusted in the field.

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Minimum Field Current (Function 7) adjusts the field-weakening level to set the top speed of the motor. The minimum field current is enabled when the armature current is less than the FW Start Current (Function 24) and the accelerator input voltage is less than 1 volt. Function 24 is used to optimize motor and controller performance.

NOTE: FW Start, Functions 24, 49, 53, 57, and 61, is not normally adjusted in the field.

NOTE: Top speed can be reduced by increasing the value of Maximum Armature percent On. Maximum Armature percent On must never be adjusted to a value less than the factory minimum value. Maximum Armature percent On is set using Function 12 (standard instrument panel) or Functions 41, 55, 59, and 63 (premium instrument panel).

Speed Limits This feature provides a means to control speed by limiting motor volts utilizing three adjustable speed limits. The lower motor volt limit always takes priority when more than one speed limit is activated. This motor volt limit regulates ON time of the transistor controller, but actual truck speed will vary at any set point depending on the loading of the lift truck. Each speed limit can be adjusted with the handset. Function 11 controls turn speed limit. Functions 12, 41, 55, 59, and 63 (Maximum Armature percent On) control main speed limit, and Function 13 controls maintenance alert speed limit.

RAMP OPERATION Ramp Start This feature provides maximum control torque to restart a lift truck on an incline. The memory for this function is the directional switch. When stopping on an incline, the directional switch must be left in its original or neutral position to allow the controller to initiate full power when restarted. The accelerator potentiometer input will modulate ramp start current.

2200 SRM 697

SX Transistor Motor Controllers

Antirollback

Pulse Monitor Trip (PMT)

This feature provides retarding torque to limit rollback speed in the nontravel direction when the accelerator pedal is released when stopping on a grade, or when the brake pedal is released when starting on a grade. This feature forces the lift truck to roll slowly down the grade when accelerator or brake is released. Because the lift truck cannot gain significant speed during rollback, the torque needed to restart on the ramp is lower than an unrestricted rollback speed.

The PMT design will disable controller operation if a fault occurs which would cause a disruption of normal lift truck operation.

STEER PUMP CONTACTOR TIME DELAY The steer pump contactor will open when the seat switch opens after the programmed time delay.

Function 18 allows adjustment of this time delay from 0.5 second to 63 seconds.

ON-BOARD COIL DRIVERS AND INTERNAL COIL SUPPRESSION The coil driver for the line contactor is internal to the controller. The line contactor must have a coil rated for the lift truck battery volts.

SYSTEM PROTECTIVE OVERRIDE SRO (Static Return to Off) If the seat switch or key switch is opened, the controller shuts off and cannot be restarted until the directional lever is returned to neutral. A time delay of approximately 2 seconds is built into the seat switch input to allow momentary opening of the seat switch.

Accelerator Volts Hold Off This feature checks the voltage level at the accelerator input whenever the key switch or seat switch is activated. If at startup, the voltage is less than 3.0 volts, the controller will not operate. This feature ensures the controller is calling for low-speed operation at startup.

The PMT circuit checks for faults three ways: • Look ahead • Look again • Automatic look again and reset Field or armature field effect transistor (FET) failure that would cause uncontrolled truck movement is considered a PMT-type fault. The controller monitors both field and armature FETs at startup and during operation. A PMT fault will not allow the line contactor to close at startup, or will open it during operation.

Thermal Protector (TP) This temperature-sensitive device is internal to the power transistor (Q1) module. If the transistor’s temperature begins to exceed the design limits, the thermal protector will lower the maximum current limit and maintain the transistors within their temperature limits. As the controller cools, the thermal protector will automatically reset, returning the controller to full power.

Low Voltage Batteries under load, particularly if undersized or more than 80 percent discharged, will produce low voltages at the controller terminals. The SX and SR controllers are designed for use down to 50 percent of a nominal battery voltage of 36 to 84 volts, and 75 percent of a nominal battery voltage of 24 volts.

Lower battery voltage may cause the controller to operate improperly, and the resulting PMT should open the line contactor in the event of a failure.

9

SR Lift Pump Controllers

2200 SRM 697

SR Lift Pump Controllers The SR controllers are sealed units with no serviceable components. User-adjustable features allow the controllers to be customized for different applications. Self-diagnostics are provided to monitor internal components as well as to detect problems with certain inputs and outputs. Adjustable parameters and status codes are accessed using a handset or a personal computer.

The SR controller is a transistorized lift pump controller capable of providing multiple lift pump speeds. Many features of the SX traction controller are incorporated into the lift pump controller.

This lift pump motor controller features: • Three speeds, adjustable from 0 to 100 percent of motor volts; the speeds are actuated by connecting the appropriate P terminal to battery negative • Adjustable current limit and controlled acceleration • Lift interrupt capability • Handset and PC programmability • Thermal protection • Low-voltage protection • Systems diagnostics • Premium instrument panel mode select capability The three speed limits are activated by the hydraulic valve PC board connecting P12, P19, and/or P20 independently to battery negative.

The first speed (Speed Limit 1) is activated by connecting P12 to battery negative. SL1 is set by Function 11. The specified motor volts will be regulated; however, motor current will vary, depending on the loading of the lift truck.

Tilt and auxiliary 1 provide the Speed Limit 1 input.

The second speed (Speed Limit 2) is activated by connecting P19 to battery negative. SL2 is set by Function 12. Operation of SL2 is similar to SL1.

10

Slow lift and auxiliary 2 provide the Speed Limit 2 input.

The third speed (Speed Limit 3) is activated by connecting P20 to battery negative. SL3 is set by Function 13. Operation of SL3 is similar to SL1.

Fast lift provides the Speed Limit 3 Input.

If more than one speed limit is activated, the selected speed with the highest motor volts will override the low motor volt speed.

The lift pump controller current limit circuit and controlled acceleration circuit are adjustable and operate the same as the traction controller circuits.

The lift interrupt feature will disable the lift pump controller when the connection at P10 loses the 12-volt signal from the traction controller. The battery discharge feature of the traction controller provides the 12-volt signal to the lift pump controller until the battery is discharged to 10 percent. Lift interrupt can be disabled by adjusting Function 17 of the lift pump controller.

The handset and PC programmability, thermal protection, low-voltage protection, systems diagnostics, and premium instrument panel mode select capability operate similar to the same features of the traction controller.

Refer to Table 2 for the SR lift pump controller connections.

Refer to Figure 8 for a typical SX traction controller schematic. See the section Wiring Diagrams 8000 SRM 696 for specific wiring details for your lift truck.

2200 SRM 697

SR Lift Pump Controllers

Table 2. SR Lift Pump Controller Connections/Descriptions/Status Codes Pin Number

Description

Wire Number

Status Code

P1

Battery Volts From Positive (BAT) Side of Key Switch

12

-

P2

Battery Volts From Negative (IGN) Side of Key Switch

10

-

P3

Power Steering Motor Brush Wear Indicator Input

106

93

P4

Power Steering Motor Brush Wear Indicator Input

105

93

P5

Left Traction Motor Brush Wear Indicator Input

104

94

P6

Right Traction Motor Brush Wear Indicator Input

103

94

P7

NOT USED

-

-

P8

Lift Pump Motor Brush Wear Indicator Input

107

95

P9

Lift Pump Motor Brush Wear Indicator Input

108

95

P10

+12 Volt Pump Enable Signal Input From Left Traction Controller

50

-

P11

Lift Pump Motor Temperature Input

102

91

P12

Speed Limit 1 Input (Tilt and Auxiliary 1)

82

-

P13

Brush Wear Indicator Output to Traction Controller

110

-

P14

Motor Overtemperature Output to Traction Controller

109

-

P15

Right Traction Motor Temperature Input

101

92

P16

Left Traction Motor Temperature Input

100

90

P17

NOT USED

-

-

P18

NOT USED

-

-

P19

Speed Limit 2 Input (Slow Lift and Auxiliary 2)

81

-

P20

Speed Limit 3 Input (Fast Lift)

84

-

P21

+5 Volt Power Supply From Left Traction Controller-NOT USED*

111

-

P22

Serial Receive - Connects to Instrument Panel

GREEN-2

-

P23

Serial Transmit - Connects to Instrument Panel

WHITE-2

-

P P L U G

*Pin is wired, but +5 volt power supply is not used by the SR lift pump controller.

11

SR Lift Pump Controllers

2200 SRM 697

Table 2. SR Lift Pump Controller Connections/Descriptions/Status Codes (Continued) Pin Number

Description

Wire Number

Status Code

PY1

Clock (Out)

-

-

PY2

Data (Out)

-

-

PY3

Enable (Out)

-

-

PY4

Negative

-

-

PY

PY5

+5 Volt Supply

-

-

P L U G

PY6

Cont/Store (In) (Handset)

-

-

PY7

External Jumper to PY12

-

-

PY8

Value

-

-

PY9

Function

-

-

PY10

External Jumper to PY11

-

-

PY11

Serial Receive/Internal Connection to P22

-

-

PY12

Serial Transmit/Internal Connection to P23

-

-

12

2200 SRM 697

SR Lift Pump Controllers

Figure 8. Typical SR Lift Pump Controller Schematic

13

Diagnostic Status Codes and Troubleshooting

2200 SRM 697

Sensor Interface/Contactor Driver Module The Sensor Interface/Contactor Driver Module (SICDM) is used with the contactor-controlled lift pump option and takes the place of the SR lift pump controller. Inputs from the hydraulic valve PC board control internal drivers, which energize the lift pump contactor(s). A 12-volt output from the

traction controller to the SICDM enables the lift pump circuit. The 12-volt signal is removed by the traction controller during lift interrupt.

See the section Electrical System 2200 SRM 698 for additional information on the SICDM.

Diagnostic Status Codes and Troubleshooting GENERAL MAINTENANCE INSTRUCTIONS

Figure 9. 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.

The transistor controller, like all electrical apparatus, does have some thermal losses. The semiconductor junctions have finite temperature limits, above which these devices may be damaged. For these reasons, normal maintenance should guard against any action which will expose the components to excessive heat and/or those conditions which will reduce the heat-dissipating ability of the controller, such as restricting airflow.

Special Precautions WARNING To avoid injury and prevent electrical shock, perform the following steps before performing any troubleshooting, adjustments, or connecting or disconnecting of a handset or PC: 1. Block the lift truck so that the drive wheels are off the floor. See the section Periodic Maintenance 8000 SRM 699 or 8000 SRM 702. Refer to How to Put Lift Truck on Blocks.

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

3. Discharge the capacitors in the controllers by connecting a 200-ohm, 2-watt resistor across the controller’s POS and NEG terminals (outer two power cable terminals). See

14

1.

2.

3.

4.

NEGATIVE POWER CABLE CONNECTION POSITIVE POWER CABLE CONNECTION 200-OHM, 2-WATT RESISTOR INSULATED JUMPER WIRES Figure 9. Discharging Capacitors

2200 SRM 697

CAUTION To avoid controller damage: 1. ALWAYS disconnect the battery when servicing the controllers.

2. ALWAYS discharge the capacitors using the proper procedure before performing any service.

3. NEVER put power to the controller with any power wire disconnected.

4. NEVER short any controller terminal or motor terminal to battery (+), battery ( ), or the frame.

Any controllers that will be applied in ambient temperatures over 40 C (100 F) should be brought to the attention of the lift truck manufacturer.

Never add unapproved accessories or components to the lift truck. All external components having inductive coils must be filtered.

The wiring should not be directly steam cleaned. In dusty areas, blow low-pressure air over the controller to remove dust. In oily or greasy areas, a mild detergent solution or denatured alcohol can be used to wash off the controller, and then low-pressure air should be used to completely dry the controller.

For the controller to be most effective, it must be mounted against the frame of the lift truck. The metal frame, acting as an additional heat sink, will give improved lift truck performance by keeping the controller package cooler. Apply a thin layer of silicone (heat transfer) grease between the controller heat sink and the lift truck frame prior to controller installation.

Controller wire plugs and other exposed transistor controller parts should be kept free of dirt and paint that might change the effective resistance between points.

CAUTION The lift truck should not be plugged when the lift truck is jacked up and the drive wheels are in a free-wheeling position. The higher motor speeds can create excessive voltages that can be harmful to the controller.

Do not subject the controller to any high voltage (hipot or megger) testing.

Diagnostic Status Codes and Troubleshooting Use a lead-acid battery with the voltage and ampere hour rating specified for the lift truck. Follow normal battery maintenance procedures, recharging before 80 percent discharged, with periodic equalizing charges.

DIAGNOSTICS Systems Diagnostics The controller detects the system’s present operating status and can display that information to either the premium instrument panel or the handset. There are currently over 70 status codes that are available with SX/SR systems using traction and lift pump controllers. The SX controller is also capable of reducing the current to the drive motor to alert the operator of a critical fault condition.

NOTE: Lift trucks without the SR pump controller are equipped with a SICDM. The SICDM performs some of the tasks of the lift pump controller and controls the lift pump contactor(s). See the section Electrical System 2200 SRM 698 for additional information on the SICDM.

STATUS CODES Standard Status Codes The SX traction controller has over 30 status codes and the SR lift pump controller has over 20 status codes to assist the service technician and operator in troubleshooting the lift truck. If a controller or controller circuit malfunction occurs, a status code is displayed on the instrument panel of lift trucks equipped with the premium instrument panel.

The premium instrument panel is capable of displaying status codes. The premium instrument panel will add a "2" prefix to all status codes received from the right traction controller to enable the operator to quickly determine which controller (left or right) is affected.

Premium Instrument Panel Status Code Readout: Left traction codes ........... no prefix.... -XX Right traction codes ........ 2 prefix ...... -2XX Pump traction codes........ 1 prefix ...... -1XX XX = Status Code

15

Diagnostic Status Codes and Troubleshooting

2200 SRM 697

Status codes can be retrieved on lift trucks without a premium instrument panel by using a standard GE handset or a PC connected through the PY plug of the controller. The handset or PC can only connect to one controller at a time. To obtain a complete list of all status codes present, EACH controller (left traction, right traction, and pump) on the lift truck must be checked, one at a time, using the handset or PC.

Maintenance Alert and Speed Limit

NOTE: The Status Code Instruction Sheets do not cover all possible causes of a display of a status code.

They provide instructions for checking the most direct inputs that can cause status codes to appear.

Battery Discharge Indication (BDI)

Procedures are outlined in Diagnostic Status Codes to determine the problem and a solution for each status code number.

Stored Status Codes This feature records the last 16 stored status codes that have caused a controller PMT shutdown and/or disrupted normal lift truck operation. (PMT-type faults are reset by cycling the key switch.) These stored status codes, along with the corresponding BDI and hourmeter readings, can be accessed with the handset, or by using the RS 232 communications port and downloading the information to a PC. Stored status codes can also be displayed on the premium instrument panel. Pushing the status code push button with the key switch in the OFF position will cause the status codes in the memory to be shown on the digital display. When the button is pushed and held down for 1 to 2 seconds, the indicator LED for the traction motor will illuminate, followed by the indicator LED for the lift pump motor. The status codes in memory will be displayed, starting with the most recent problem. The system will go through 16 left traction motor codes, followed by 16 right traction motor codes, then 16 lift pump motor codes. If the button is pushed again, the display will start from the beginning. A handset or PC must be used to clear the status codes stored in the register.

OTHER FEATURES Hourmeter Readings This feature will display the recorded hours of use of the traction controller and pump controller to the instrument panel each time the key switch is turned off.

16

This feature is used to display Status Code 99 and/or activate a speed limit when the lift truck operating hours match the hours set in the maintenance alert register. This feature is set with the handset using Functions 19, 20, and 13. The operator is alerted that maintenance on the lift truck is required.

The latest in microprocessor technology is used to provide accurate battery state-of-charge information and to supply passive and active warning signals to the lift truck operator.

Features and functions: • Displays 100 to 0 percent charge.

• Display blinks with 20 percent charge. Disables lift pump circuit with 10 percent charge. Autoranging for 36- or 48-volt operation. Adjustable for use on 24 to 80 volts.

Internal Resistance Compensation This feature is used when the battery discharge indicator is present. Adjustment of this function will improve the accuracy of the BDI.

Handset Programmable This is a multifunctional tool used with the LX, ZX, and SX series GE solid-state controllers. The handset consists of a Light-Emitting Diode (LED) display and a keyboard for data entry.

Features and functions: • Monitor existing system status codes for both traction and pump controllers. Monitor intermittent random status codes.

• Monitor battery state of charge, if available.

• Monitor hourmeter reading on traction and pump controllers. Monitor or adjust the controller functions.

RS 232 Communication Ports The P and PY plugs are used as serial communication ports. Premium instrument panels interface with the controllers through the P plug. A handset or PC is connected to the PY plug. This arrangement allows the use of a handset or a PC without disconnecting the instrument panel.

2200 SRM 697

Diagnostic Status Codes and Troubleshooting

Circuit Board Coil Driver Modules

lift pump controller (transistor lift pump control) or the sensor interface/contactor driver module (contactor lift pump control). See the section Electrical System 2200 SRM 698 for additional information on the SICDM.

The line contactor is controlled by the traction controller. The controller has an internal driver for the contactor and provides reverse battery protection. If the battery is connected incorrectly, the contactors cannot be closed electrically.

Interactive Instrument Panel Modes

Maintenance Management Capability

Premium instrument panels allow the operator to select the best lift truck performance for different conditions. There are four modes that can be selected by depressing a push button on the instrument panel.

The SX traction controller has the capability of monitoring certain maintenance items. The hourmeter reading is monitored and can be used to provide a maintenance alert when a preprogrammed hourmeter reading is reached. Brush wear and motor temperature can also be monitored. Temperature sensors can be present on the traction and lift pump motors. Brush wear sensors can be present on the traction, lift pump, and steer pump motors.

From the instrument panel, the operator may select any of four preset interactive modes.

TRACTION CONTROLLER (4) Controlled acceleration levels (4) Field-weakening levels (FW Start and FW Ratio) (4) Speed limits

The traction controller will set a status code and reduce maximum lift truck speed if the maintenance alert hourmeter reading is reached, or if an optional temperature sensor determines that a motor is overheated.

LIFT PUMP CONTROLLER (4) Controlled acceleration levels (4) Speed Limit 2 levels (Slow Lift, Auxiliary 2) (4) Speed Limit 3 levels (Fast Lift)

The traction controller will set a status code if an optional brush wear indicator detects a worn brush.

NOTE: Traction controller Functions 3, 24, 6, and 12 are disregarded when using the premium instrument panel with mode selection. See Table 3.

The maintenance alert hourmeter reading is programmed into the traction controller using Function 19 and Function 20.

NOTE: Lift pump controller Functions 3, 12, and 13 are disregarded when using the premium instrument panel with mode selection. See Table 3.

NOTE: The brush wear and motor temperature inputs to the traction controller are received from the Table 3. Instrument Panel Function Number Correlation

Function Description

Traction Controller

Lift Pump Controller

Standard Dash Function Number (Without mode selection)

Premium Dash Function Number Mode 1 Mode 2 Mode 3 Mode 4

Controlled Acceleration

3

48

52

56

60

FW Start

24

49

53

57

61

FW Ratio

6

50

54

58

62

Maximum Armature % On

12

51

55

59

63

Controlled Acceleration

3

48

52

56

60

Speed Limit 2

12

49

53

57

61

Speed Limit 3

13

50

54

58

62

17

Diagnostic Status Codes and Troubleshooting

2200 SRM 697

These interactive modes are preset using function numbers: Handset

PC

Traction Controller

48 to 63

97 to 112

Lift Pump Controller

48 to 62

97 to 111

Table 4 outlines the normal logic flow for presetting the interactive traction modes.

Table 5 outlines the normal logic flow for presetting the interactive lift pump modes.

Table 4. Traction Function Settings Logic Mode 1 "Turtle"

Controlled Acceleration (C/A)

Equal to or greater than Mode 2 Function 48

Field Weakening Start (FW Start)

Equal to or less than Mode 2

USE FACTORY VALUES

Function 49

Mode 2

Mode 3

Equal to or greater than Mode 3

Equal to or greater than Mode 4

Equal to or less than Mode 1

Equal to or less than Mode 2

Function 52

Function 56

Equal to or less than Mode 3

Equal to or less than Mode 4

Equal to or greater than Mode 1

Equal to or greater than Mode 2

Function 53

Function 57

Mode 4 "Rabbit" Equal to or less than Mode 3 Function 60 Equal to or greater than Mode 3 Function 61

WARNING Field Weakening Start is not normally adjusted in the field. Adjusting Field Weakening Start between the minimum and maximum values will not alter lift truck performance.

Field Weakening Ratio (FW Ratio) USE FACTORY VALUES

Equal to or greater than Mode 2

Function 50

Equal to or greater than Mode 3

Equal to or greater than Mode 4

Equal to or less than Mode 1

Equal to or less than Mode 2

Function 54

Function 58

Equal to or less than Mode 3 Function 62

WARNING Field Weakening Ratio is not normally adjusted in the field. Adjusting Field Weakening Ratio between the minimum and maximum values will not alter lift truck performance.

Top Travel Speed Limit (SL2)

Equal to or greater than Mode 2 Function 51

18

Equal to or greater than Mode 3

Equal to or greater than Mode 4

Equal to or less than Mode 1

Equal to or less than Mode 2

Function 55

Function 59

Equal to or less than Mode 3 Function 63

2200 SRM 697

Diagnostic Status Codes and Troubleshooting Table 5. Lift Pump Function Settings Logic Mode 1 "Turtle"

Controlled Acceleration (C/A)

Equal to or greater than Mode 2 Function 48

Speed Limit 2 (SL2) Slow Lift, Auxiliary

Equal to or less than Mode 2 Function 49

Speed Limit 3 (SL3) Fast Lift

Equal to or less than Mode 2 Function 50

Mode 2

Mode 3

Equal to or greater than Mode 3

Equal to or greater than Mode 4

Equal to or less than Mode 1

Equal to or less than Mode 2

Function 52

Function 56

Equal to or less than Mode 3

Equal to or less than Mode 4

Equal to or greater than Mode 1

Equal to or greater than Mode 2

Function 53

Function 57

Equal to or less than Mode 3

Equal to or less than Mode 4

Equal to or greater than Mode 1

Equal to or greater than Mode 2

Function 54

Function 58

GENERAL TROUBLESHOOTING INSTRUCTIONS The SX and SR controllers are sealed units with no serviceable components. Troubleshooting is usually limited to accessing status codes and following the diagnostic procedures listed in the Status Code Troubleshooting Tables.

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

CAUTION Never attempt to probe through the back of the controller or sensor interface contactor driver module plugs. 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,

Mode 4 "Rabbit" Equal to or less than Mode 3 Function 60 Equal to or greater than Mode 3 Function 61 Equal to or greater than Mode 3 Function 62

check for voltage at an amp-type plug, a switch, or a component. If a circuit is suspect, check the circuit for continuity by disconnecting the P plug and testing continuity from the front (pin end) of the plug.

CAUTION Standard probes are too large to be inserted into the center of the female pins (sockets) of the special sealed plugs and can expand the pins. Expanded pins will not provide good connections once the plug is reconnected. To prevent pin damage, only use probes with a diameter of 1.57 mm (0.062 in.) or less.

Refer to Table 1 for the SX traction controller connections. Refer to Table 2 for the SR lift pump controller connections. Refer to Figure 10 for the transistor controller plug pin out.

19

Diagnostic Status Codes and Troubleshooting

A. WIRE END VIEW, PY PLUG

2200 SRM 697

B. WIRE END VIEW, P PLUG

Figure 10. Transistor Controller Plug Pin Out See the section Wiring Diagrams 8000 SRM 696 for additional wiring details.

If misoperation of the lift truck occurs, a status code is displayed on the instrument panel for lift trucks equipped with a premium instrument panel. On lift trucks without the premium instrument panel, status codes are accessed by plugging a handset into the PY plug of each controller.

have been followed and no problem is found, the controller should then be replaced as the last option to correct the problem.

Check resistance on R × 1000 scale from frame to power and controller terminals. A resistance of less than 20,000 ohms can cause misleading symptoms.

Resistance less than 1000 ohms should be corrected first.

Once the status code number is obtained, follow the procedures outlined in the Status Code Troubleshooting Tables to determine the problem.

Before proceeding, visually check for loose wiring, misaligned linkage to the accelerator switch, signs of overheating of components, etc.

NOTE: Due to the interaction of the controller with all lift truck functions, almost any status code or controller fault could be caused by an internal failure of the controller. After all other status code procedures

Tools and test equipment required are clip leads, volt-ohmmeter (20,000 ohms per volt), and basic hand tools.

20

2200 SRM 697

Status Code Troubleshooting Tables

Status Code Troubleshooting Tables Status Code

Description

Memory Recall

Circuit

NONE

Segments do not illuminate on the instrument panel and/or the handset.

No

Traction and Pump

Symptom Display screen on instrument panel and/or handset is blank.

Possible Causes and Test Procedures • Positive or negative controller voltage is not present.

Ensure that the key switch is closed and voltage is present between P1 and battery negative (negative standoff). Also, check for voltage between P2 and controller negative (B ).

• Open circuit between controller PY plug and the handset.

Check for an open circuit or loose connection going from the PY plug to the handset.

• Open circuit between controller P plug and the instrument panel.

Check for an open circuit or loose connection going from the P plug to the instrument panel.

• Defective instrument panel or handset.

Replace instrument panel or handset.

Cause No input voltage to the controller or the display unit.

Status Code

Description

Memory Recall

Circuit

-01

No seat switch input.

No

Traction

Symptom Traction is disabled.

Possible Causes and Test Procedures • Seat switch defective.

Check to see that the seat switch operates properly.

Replace a failed switch.

• Open circuit between battery positive and P6.

Check for loose connections or broken wires: Between the seat switch and P6 Between the key switch and the battery positive side of the seat switch Between the seat switch and P6

Cause This status code is displayed when P6 is less than 50 percent of battery voltage.

21

Status Code Troubleshooting Tables

2200 SRM 697

Status Code

Description

Memory Recall

Circuit

-02

Forward directional switch is closed on initial powerup.

No

Traction

Symptom Controller will not operate because of Static Return to Off (SRO) lockout.

Possible Causes and Test Procedures • Forward directional switch is closed on initial startup.

Example: Forward directional switch is closed before battery is connected or before key switch or seat switch is closed.

Return directional switch lever to NEUTRAL and then return lever to FORWARD position.

• Forward directional switch is failed closed or out of adjustment (adjusted to be held closed).

Replace or adjust directional switch to ensure it opens when the directional switch is returned to neutral.

• Short circuit between P3 and P4.

Disconnect the wire from P4 and check for a short circuit between P3 and the wire that was connected to P4.

• Malfunctioning controller.

Replace the traction controller.

22

Cause This status code is displayed when P4 is greater than 60 percent of battery voltage at initial key switch on.

2200 SRM 697

Status Code Troubleshooting Tables

Status Code

Description

Memory Recall

Circuit

-03

Reverse directional switch is closed on initial powerup.

No

Traction

Symptom Controller will not operate because of Static Return to Off (SRO) lockout.

Possible Causes and Test Procedures • Reverse directional switch is closed on initial startup.

Example: Reverse directional switch is closed before battery is connected or before key switch or seat switch is closed.

Return directional switch lever to NEUTRAL and then return lever to REVERSE position.

• Reverse directional switch is failed closed or out of adjustment (adjusted to be held closed).

Replace or adjust directional switch to ensure it opens when the directional switch is returned to NEUTRAL. • Short circuit between P3 and P5.

Disconnect the wire from P5 and check for a short circuit between P3 and the wire that was connected to P5.

• Malfunctioning controller.

Replace the traction controller.

Cause This status code is displayed when P5 is greater than 60 percent of battery voltage at initial key switch on.

23

Status Code Troubleshooting Tables

2200 SRM 697

Status Code

Description

Memory Recall

Circuit

-05

Start switch fails to close.

No

Traction

Symptom Traction is disabled.

Possible Causes and Test Procedures • Defective start switch circuit.

Check for open circuit or loose connections in wiring from key switch to accelerator speed control unit and from P3 to accelerator speed control unit.

• Defective accelerator speed control unit.

Check accelerator speed control unit for proper operation and output.

Accelerator speed control unit wiring: YELLOW - not used RED - Wire 10 - Battery positive input from key switch BLACK - Wire 13 - Battery negative WHITE - Wire 15 - Output from start switch to P3 P3 (PEDAL UP) 0.0 volts P3 (CREEP to FULLY DEPRESSED) battery volts GREEN - Wire 29 - Output from speed control to P7 P7 (PEDAL UP) 3.5 ±0.05 volts P7 (PEDAL FULLY DEPRESSED) 0.1 volt or less NOTE: The accelerator speed control unit is not serviceable and must be replaced as an assembly.

24

Cause This status code is displayed when P7 is less than 2.5 volts and P3 is less than 60 percent of battery voltage.

2200 SRM 697

Status Code Troubleshooting Tables

Status Code

Description

Memory Recall

Circuit

-06

Accelerator depressed with no direction selected.

No

Traction

Symptom Traction is disabled.

Possible Causes and Test Procedures • Accelerator pedal is depressed before closing forward or reverse directional switch.

Status code will disappear when directional switch is closed or when accelerator pedal is released.

• Defective directional switch.

Check forward or reverse switch to ensure continuity when direction is selected.

• Open circuit between directional switch and battery positive or between directional switch and P4 or P5.

Check all wires and connections shown in troubleshooting diagram.

Cause This status code is displayed when P4 and P5 are less than 60 percent of battery voltage, and P7 is less than 2.5 volts.

Status Code

Description

Memory Recall

Circuit

-07

Accelerator input voltage too high when key switch is initially closed.

No

Traction

Symptom Controller will not operate when accelerator pedal is depressed or status code -07 is displayed then disappears when the lift truck starts to accelerate.

Possible Causes and Test Procedures • Accelerator speed control unit out of adjustment or defective.

Input voltage at P7 should be less than 4.2 volts.

Adjust or replace accelerator speed control unit to ensure that the voltage at P7 will vary from 3.5 volts (pedal up) to less than 0.5 volt (pedal fully depressed).

• Open circuit between P7 and accelerator speed control unit.

Check for broken wires or loose connections.

• Short circuit from battery positive to wiring in accelerator input circuit.

Disconnect wire from P7 and measure voltage at wire to negative. Should be less than 4.2 volts for solid-state accelerator speed control unit.

Cause This status code is displayed when the accelerator input voltage at P7 is higher than 4.2 volts and a directional switch is closed.

NOTE: Refer to status code -05 for accelerator speed control unit voltage specifications.

25

Status Code Troubleshooting Tables

2200 SRM 697

Status Code

Description

Memory Recall

Circuit

-08

Accelerator input voltage too low when key switch is initially closed.

No

Traction

Symptom Traction is disabled.

Possible Causes and Test Procedures • Accelerator speed control unit out of adjustment or defective.

Input voltage at P7 should be more than 3.0 volts. Adjust or replace accelerator unit to ensure that the voltage at P7 is more than 3.0 volts before depressing pedal.

• Short circuit between battery negative and P7 in accelerator input circuit.

Disconnect wire from P7 and measure voltage at wire to negative. Voltage should be greater than 3.0 volts for solid-state accelerator speed control unit.

• Defective controller.

Disconnect wire from P7. Measure voltage from P7 to negative. Voltage should be greater than 4.5 volts. If not, replace controller.

Cause This status code is displayed when the accelerator input voltage at P7 is less than 3.0 volts and any of the following connections are opened and closed: battery plug, seat switch, or key switch.

NOTE: Refer to status code -05 for accelerator speed control unit voltage specifications.

Status Code

Description

Memory Recall

Circuit

-09

Both the forward and reverse directional switches are closed at the same time.

No

Traction

Symptom Traction is disabled.

Possible Causes and Test Procedures • Forward or reverse directional switch is failed, closed, or out of adjustment (adjusted to be held closed).

Replace or adjust directional switches to ensure they open when directional switch is returned to neutral.

• Short circuit between positive and P4 and/or P5.

Disconnect wires from P4 and P5 and check wire for short circuit to positive side of directional switches.

• Malfunctioning controller.

Disconnect wires and measure voltage at P4 and P5. Voltage should be less than 60 percent of battery volts.

26

Cause This status code is displayed when P4 and P5 are greater than 60 percent of battery voltage at the same time.

2200 SRM 697

Status Code Troubleshooting Tables

Status Code

Description

Memory Recall

Circuit

-10

Steer angle potentiometer voltage is too high.

Yes

Traction

Symptom Traction is disabled.

Possible Causes and Test Procedures • Steer angle potentiometer out of adjustment.

Verify that the steer angle potentiometer is adjusted properly. See the section Electrical System 2200 SRM 698. Refer to Steer Angle Potentiometer, Adjust.

• Steer angle potentiometer defective.

Check the steer angle potentiometer for proper operation. See the section Electrical System 2200 SRM 698. Refer to Steer Angle Potentiometer, Test.

• Loose or missing connections at P8, P12, or P9.

Disconnect the P plug and the potentiometer and check continuity: Between P8 and pot terminal 1 Between P12 and pot terminal 2 Between P9 and pot terminal 3 • Malfunctioning controller.

Replace controller.

Cause This status code is displayed when P12 is greater than 3.9 volts.

NOTE: Input voltage at P12 should be less than 3.9 volts at all times.

27

Status Code Troubleshooting Tables

2200 SRM 697

Status Code

Description

Memory Recall

Circuit

-11

Start switch closed on powerup after initial key switch closure.

No

Traction

Symptom Traction is disabled.

Possible Causes and Test Procedures • Start switch out of adjustment or defective.

Input volts at P3 should be less than 60 percent of battery voltage at key switch closing. Adjust or replace accelerator speed control unit to ensure that the voltage at P3 is less than 60 percent of battery volts before closing the start switch pedal.

• Short circuit between battery positive and P3 in start switch input circuit.

Disconnect wires at accelerator speed control unit.

Disconnect wire from P3 and check for short circuit from wire to battery positive.

• Malfunctioning controller.

Disconnect wire from P3. Measure voltage from P3 to negative. Voltage should be zero. If not, replace controller.

NOTE: The accelerator speed control unit is not serviceable and must be replaced as an assembly.

NOTE: Refer to status code -05 for accelerator speed control unit voltage specifications.

28

Cause This status code is displayed when P3 is greater than 60 percent of battery voltage when the key switch is closed.

2200 SRM 697

Status Code Troubleshooting Tables

Status Code

Description

Memory Recall

Circuit

-12

Steer angle potentiometer voltage is too low.

Yes

Traction

Symptom Traction is disabled.

Possible Causes and Test Procedures • Steer angle potentiometer out of adjustment.

Verify that the steer angle potentiometer is adjusted properly. See the section Electrical System 2200 SRM 698. Refer to Steer Angle Potentiometer, Adjust.

• Steer angle potentiometer defective.

Check the steer angle potentiometer for proper operation. See the section Electrical System 2200 SRM 698. Refer to Steer Angle Potentiometer, Test.

• Loose or missing connections at P8, P12, or P9.

Disconnect the P plug and the potentiometer and check continuity: Between P8 and pot terminal 1 Between P12 and pot terminal 2 Between P9 and pot terminal 3 • Malfunctioning controller.

Replace controller.

Cause This status code is displayed when P12 is less than 0.39 volt.

NOTE: Input voltage at P12 should be greater than 0.39 volt at all times.

29

Status Code Troubleshooting Tables

2200 SRM 697

Status Code

Description

Memory Recall

Circuit

-15

Battery voltage is too low or controller is adjusted to the wrong battery voltage.

No

Traction

Symptom Traction is disabled.

Possible Causes and Test Procedures • Discharged battery.

Check battery for proper open circuit voltage.

Correct voltages are listed on right.

Charge battery, if required.

• Defective battery.

Check each battery cell for proper voltage (greater than 1.95 volts at cell). Replace or repair battery.

• Incorrect controller adjustment.

Check Function 15 for proper adjustment for the battery being used. Adjust to proper settings.

Refer to SX/SR Handset Instructions. See Table 7, Table 8, and Table 9 for the Function 15 value for your lift truck.

• Minimum battery volts not present between P1 and NEG. Check for battery volts between P1 and negative standoff. If battery volts are not present, check for a voltage drop between battery (+) and P1 and/or between battery ( ) and negative standoff.

30

Cause This status code is displayed when the battery volts are less than 1.95 volts per cell at initial key switch on.

2200 SRM 697

Status Code Troubleshooting Tables

Status Code

Description

Memory Recall

Circuit

-16

Battery voltage is too high or controller is adjusted to the wrong battery voltage.

No

Traction

Symptom Traction is disabled.

Possible Causes and Test Procedures • Incorrect controller adjustment.

Check Function 15 for proper adjustment for the battery being used. Adjust to proper setting. Refer to SX/SR Handset Instructions. See Table 7, Table 8, and Table 9 for the Function 15 value for your lift truck.

• Battery overcharged or incorrect battery used.

Check battery for proper open circuit voltage.

Correct voltages are listed on right.

If voltage is excessive, check battery charger for proper output voltage.

Cause This status code is displayed when the battery volts are greater than 24 volts per cell at initial key switch on.

Status Code

Description

Memory Recall

Circuit

-17

"Controller Type" selection is invalid.

No

Traction

Symptom Traction is disabled.

Possible Causes and Test Procedures • Invalid "controller type" selection.

Check the setting of Function 17. Adjust Function 17 to the value listed for your lift truck as shown in Table 7, Table 8, and Table 9.

Cause This status code is displayed when the controller type selection value is set to an invalid number.

31

Status Code Troubleshooting Tables

2200 SRM 697

Status Code

Description

Memory Recall

Circuit

-23

Motor field current is high at startup in the reverse direction.

No

Traction

Symptom Maximum travel speed is reduced or traction is disabled.

Possible Causes and Test Procedures • Malfunctioning controller.

Replace the traction controller.

Cause This status code is displayed when the current draw in the motor field is too high at startup in the reverse direction.

Status Code

Description

Memory Recall

Circuit

-24

Motor field current is high at startup in the forward direction.

No

Traction

Symptom Maximum travel speed is reduced or traction is disabled.

Possible Causes and Test Procedures • Malfunctioning controller.

Replace the traction controller.

Cause This status code is displayed when the current draw in the motor field is too high at startup in the forward direction.

32

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Status Code Troubleshooting Tables

Status Code

Description

Memory Recall

Circuit

-27

Internal power supply is less than 10 VDC.

Yes

Traction

Symptom Line contactor closes and opens, then can only be closed by opening and closing the key switch.

Possible Causes and Test Procedures • Discharged battery.

Check battery to ensure proper start of charge.

Voltage may be dropping below 10 VDC under load.

• Loose connection at P1.

Ensure the wire connection at P1 is tight.

• Malfunctioning controller.

Replace the traction controller.

Cause This status code is displayed when the controller’s internal power supply is less than 10 volts.

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Status Code Troubleshooting Tables

2200 SRM 697

Status Code

Description

Memory Recall

Circuit

-28

Drive motor field current exceeds design limit for a 70-second period.

Yes

Traction

Symptom If one controller detects excessive field current: The controller detecting the excessive field current will shut down. The remaining controller and drive motor will continue to operate normally for approximately 16 seconds. After 16 seconds, fault code 29 is set and travel speed is reduced.

If both controllers detect excessive field current: Both controllers will shut down and traction will be disabled.

Possible Causes and Test Procedures • Operation of lift truck in high motor current condition.

Turn key switch OFF and restart truck normally to clear code.

Verify lift truck is being operated properly. Multiple code 28’s stored in memory can indicate that the lift truck is frequently being operated improperly.

Instruct operator to avoid stall conditions, pushing loads, excessive ramp grades, etc.

• Function 7 is improperly adjusted to allow higherthan-normal motor field current.

Adjust Function 7 to the value listed for your lift truck as shown in Table 7, Table 8, and Table 9.

NOTE: A status code 28 retained in memory may indicate that, at some time in the past, the controller has detected a high-current situation and that the code was cleared by cycling the key switch OFF and ON.

34

Cause This status code is displayed during the run mode when the controller determines that motor field current is above the design limit* for longer than approximately 70 seconds. *Design limit for SX 450 controller is 30 amps.

2200 SRM 697

Status Code Troubleshooting Tables

Status Code

Description

Memory Recall

Circuit

-29

Opposite drive motor inoperative.

Yes

Traction

Symptom Maximum travel speed is reduced.

Travel speed is limited to the value set

by Function 13.

Possible Causes and Test Procedures • Opposite controller inoperative or operating in "slow down" mode.

Verify proper operation of both controllers in the run mode.

NOTE: A status code 29 retained in memory may indicate that, at some time in the past, the controller has detected one inoperative controller and that the code was cleared by cycling the key switch OFF and ON. A high-current situation may cause one controller to shut down and would be indicated by a status code 28 being stored in memory.

NOTE: Function 13, speed limit 3 is enabled by this status code.

Cause This status code is displayed when the current in one drive motor is greater than 98 amps while the current in the other drive motor is less than 28 amps for a 16-second period.

NOTE: When a controller shuts down and a status code 29 is set, code 29 is always set in the controller that remains operative.

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Status Code Troubleshooting Tables

2200 SRM 697

Status Code

Description

Memory Recall

Circuit

-41

Open thermal protector (TP) or transistor overtemperature.

No

Traction

Symptom Maximum travel speed is reduced or traction is disabled.

Possible Causes and Test Procedures • Controller is in thermal cutback.

[Controller heat sink (metal mounting base) temperature is in excess of 60 C (140 F).]

Allow controller to cool; status code should disappear.

• Internal thermal protector has failed.

Measure the controller heat sink (metal mounting base) temperature during thermal cutback. Heat sink temperatures less than 60 C (140 F) during thermal cutback indicate a faulty thermal protector.

Replace lift pump controller.

Cause This status code is displayed when the voltage at the internal thermal protector is greater than 0.8 volt.

Status Code

Description

Memory Recall

Circuit

-42

Motor armature offset voltage is too high.

No

Traction

Symptom Maximum travel speed is reduced or traction is disabled.

Possible Causes and Test Procedures • Controller is defective.

Replace the traction controller.

Cause This status code is displayed when the voltage at the internal current sensor input is greater than 2.6 volts with no current flowing in the motor circuit.

36

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Status Code Troubleshooting Tables

Status Code

Description

Memory Recall

Circuit

-43

Motor armature offset voltage is too low.

No

Traction

Symptom Maximum travel speed is reduced or traction is disabled.

Possible Causes and Test Procedures • Controller is defective.

Replace the traction controller.

Cause This status code is displayed when the voltage at the current sensor input is less than 2.4 volts with no current flowing in the motor circuit.

Status Code

Description

Memory Recall

Circuit

-44

Armature transistor did not turn off properly.

Yes

Traction

Symptom Traction is disabled.

Line contactor may open, close, and then open again. Line contactor can then only be closed by opening and closing the key switch.

Possible Causes and Test Procedures • Malfunctioning controller.

Replace the traction controller.

Cause This status code is displayed when, during controller operation, the armature transistor fails to turn off. This will result in a PMT condition.

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Status Code Troubleshooting Tables

2200 SRM 697

Status Code

Description

Memory Recall

Circuit

-45

Armature transistor did not turn on properly.

Yes

Traction

Symptom Traction is disabled.

Line contactor may open, close, and then open again. Line contactor can then only be closed by opening and closing the key switch.

Possible Causes and Test Procedures • Malfunctioning controller.

Replace the traction controller.

Cause This status code is displayed when, during controller operation, the armature transistor fails to turn on properly.

This will result in a PMT condition.

Status Code

Description

Memory Recall

Circuit

-46

"Look Ahead" test for A2 volts less than 12 percent of battery voltage.

No

Traction

Symptom Traction is disabled.

Line contactor will not close.

Possible Causes and Test Procedures • Check for short circuit from the motor armature to the frame of the lift truck.

• Malfunctioning controller.

Replace the traction controller.

Cause This status code is displayed when the voltage at A2 is less than 12 percent of battery voltage.

38

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Status Code Troubleshooting Tables

Status Code

Description

Memory Recall

Circuit

-49

Motor field current is too low during the run mode.

No

Traction

Symptom Maximum travel speed is reduced or traction is disabled.

Possible Causes and Test Procedures • Malfunctioning controller.

Replace the traction controller.

Cause This status code is displayed when the current draw in the motor field is too low during the run mode.

Status Code

Description

Memory Recall

Circuit

-51

Capacitor volts are low before the line contactor closes.

No

Traction

Symptom Traction is disabled.

Line contactor does not close.

Controller capacitor does not precharge.

Possible Causes and Test Procedures • Failed controller fuse.

Check controller fuse for open circuit. Replace fuse, if necessary.

• Malfunctioning controller.

Replace the traction controller.

• Accessory or component other than controllers connected to load side of line contactor.

Verify that the traction and lift pump controllers are the only components on the load side of the line contactor.

NOTE: Repeated charging/discharging of the capacitors during troubleshooting can cause status code 51.

Cause This status code is displayed during "key on" when the capacitor voltage is less than 85 percent of battery voltage at initial key switch on.

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Status Code Troubleshooting Tables

2200 SRM 697

Status Code

Description

Memory Recall

Circuit

-52

Line contactor driver shorted on startup.

No

Traction

Symptom Traction is disabled.

Line contactor does not close.

Possible Causes and Test Procedures • Malfunctioning controller.

Replace the traction controller.

Cause This status code is displayed when the controller detects a shorted line contactor driver during startup.

Status Code

Description

Memory Recall

Circuit

-57

Controller motor current sensor input too low during running.

No

Traction

Symptom Maximum travel speed is reduced or traction is disabled.

Possible Causes and Test Procedures • Malfunctioning controller.

Replace the traction controller.

Cause This status code is displayed when the voltage input from the current sensor is too low during running.

40

2200 SRM 697

Status Code Troubleshooting Tables

Status Code

Description

Memory Recall

Circuit

-64

Line driver input (P2-17) is less than 12 percent of battery voltage.

No

Traction

Symptom Motor controller will not operate.

Possible Causes and Test Procedures • Open or loose connection to pin 17.

Check for loose or broken wire at plug pin P7.

• Malfunction of driver transistor in motor controller.

Replace the motor controller.

Cause This status code is displayed when the controller detects that the line driver input (P2-17) is less than 12 percent of battery voltage with the key switch in the ON position.

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Status Code Troubleshooting Tables

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Status Code

Description

Memory Recall

Circuit

-65

The line coil current is too high during the run mode.

Yes

Traction

Symptom Motor controller will not operate.

Possible Causes and Test Procedures • Line contactor coil has a short circuit.

Disconnect the wires at the coil terminals of the line contactor and check for the correct resistance between the terminals.

• Short circuit of coil wires (wires 10 and 24) of the line contactor.

Make sure key switch is OFF. Disconnect the wires at the coil terminals of the line contactor and check for a short circuit between the wires.

• Malfunction of motor controller.

Replace the motor controller.

Cause This status code is displayed when the current limit in the line coil is exceeded. The line contactor will drop out and the key switch must be moved to OFF to reset the control.

42

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Status Code Troubleshooting Tables

Status Code

Description

Memory Recall

Circuit

-66

The field current exceeds the current limit of the field transistor.

Yes

Traction

Symptom Motor controller will not operate (line contactor drops out).

Possible Causes and Test Procedures • Short circuit in field circuit of traction motor.

Disconnect power leads at traction motor F1 and F2 terminals and check for a short circuit between power leads.

Check for battery positive at both F1 and F2 terminals.

Check for battery negative at both F1 and F2 terminals.

Check for a short circuit between motor terminal F1 and motor case.

Check for a short circuit between motor terminal F2 and motor case.

Cause This status code is displayed when the field transistor current is greater than the current limit setting. The line contactor will drop out, and the controller is reset by recycling key switch.

Status Code

Description

Memory Recall

Circuit

-67

The armature current exceeds the armature transistor limit.

Yes

Traction

Symptom Control will not operate (line contactor drops out).

Possible Causes and Test Procedures • Shorted armature A1 to A2.

Disconnect power cables from the traction motor terminals A1 and A2. Check for a short circuit between the terminals.

• Short circuit of armature terminal A1 and A2 to battery positive or battery negative.

Disconnect power cables from traction motor terminals A1 and A2. Check for a short circuit between each terminal to battery positive and then each terminal to battery negative.

• Short circuit between power cables to the armature terminals (A1 and A2).

Disconnect the power cables from traction motor terminals A1 and A2. Check for a short circuit between the power cables.

Cause This status code is displayed when the armature transistor exceeds its specific current limit. The control is reset by recycling the key switch.

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Status Code Troubleshooting Tables

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Status Code

Description

Memory Recall

Circuit

-69

The field current exceeds the current limit of the field transistor.

Yes

Traction

Symptom Control will not operate (line and power steering contactors drop out).

Possible Causes and Test Procedures • Short circuit in coil of power steering contactor or wires connected to coil.

Disconnect wires connected to coil of power steering contactor. Check for a short circuit between coil terminals. Check for a short circuit between coil wires 10 and 60.

• Malfunction of motor controller.

Replace traction motor controller.

Cause This status code is displayed when the current in the power steering driver circuit exceeds current limit during the run mode. The control is reset by recycling the key switch.

Status Code

Description

Memory Recall

Circuit

-76

Capacitor (1C) voltage too high.

Yes

Traction

Symptom Traction is disabled.

Line contactor will open, close, and then open again. Line contactor can then only be closed by opening and closing the key switch.

Possible Causes and Test Procedures • Unplugging the battery connector during regenerative braking.

Do not unplug the battery while the lift truck is in operation.

• Line contactor bouncing open during regen.

Check line contactor for proper operation.

• Main power fuse opening during regen.

Check fuse and fuse connections.

• Intermittent battery plug connection.

Check connections from battery positive to controller positive.

44

Cause This status code is displayed when the voltage on the capacitor goes above 70 volts during the regenerative braking cycle.

2200 SRM 697

Status Code Troubleshooting Tables

Status Code

Description

Memory Recall

Circuit

-77

Motoring current is detected during regenerative braking.

Yes

Traction

Symptom Traction is disabled.

Line contactor will open, close, and then open again. Line contactor can then only be closed by opening and closing the key switch.

Possible Causes and Test Procedures • Malfunctioning controller.

Replace the traction controller.

Cause This status code is displayed when motoring current is detected during the regenerative braking cycle.

Status Code

Description

Memory Recall

Circuit

-82

If the armature motor current is greater than 450 amps for longer than 3.5 seconds, the armature motoring current will be turned off.

No

Traction

Symptom The motor controller will not operate and can only be reset by cycling the key switch.

Possible Causes and Test Procedures • Continued operation of vehicle in high motor current condition.

• Operating control at stall motor current for more than 3.5 seconds.

• Function 16 is incorrectly adjusted for control percent on time.

Adjust function per OEM instructions.

Cause This status code is displayed when the armature motor current exceeds 450 amps for 3.5 seconds and the accelerator pedal is calling for maximum performance.

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Status Code Troubleshooting Tables

2200 SRM 697

Status Code

Description

Memory Recall

Circuit

-90

Left traction motor temperature too high.

No

Traction and Pump

Symptom Status code flashes on and off.

Possible Causes and Test Procedures • Left traction motor is too hot.

Allow left traction motor to cool.

If problem recurs, determine reason for overheating traction motor and correct.

• P16 is shorted to battery negative.

Locate and repair short.

• Left traction motor temperature sensor is shorted or defective.

Replace temperature sensor.

• Defective lift pump controller.

(SR transistor-controlled lift pump only.)

Replace the lift pump controller.

• Defective sensor interface/contactor driver module.

(Contactor-controlled lift pump only.)

Replace the sensor interface/contactor driver module.

NOTE: Function 13, speed limit 3 is enabled by this status code.

46

Cause This status code is displayed when the voltage at terminal P16 of the SR lift pump controller or the sensor interface/contactor driver module is at zero volts.

2200 SRM 697

Status Code Troubleshooting Tables

Status Code

Description

Memory Recall

Circuit

-91

Lift pump motor temperature too high.

No

Traction and Pump

Symptom Status code flashes on and off.

Maximum travel speed is reduced.

Possible Causes and Test Procedures • Lift pump motor is too hot.

Allow lift pump motor to cool.

If problem recurs, determine reason for overheating lift pump motor and correct.

• P11 is shorted to battery negative.

Locate and repair short.

• Lift pump motor temperature sensor is shorted or defective.

Replace temperature sensor.

• Defective lift pump controller.

(SR transistor-controlled lift pump only.)

Replace the lift pump controller.

• Defective sensor interface/contactor driver module.

(Contactor-controlled lift pump only.)

Replace the sensor interface/contactor driver module.

Cause This status code is displayed when the voltage at terminal P11 of the SR lift pump controller or the sensor interface/contactor driver module is at zero volts.

NOTE: Function 13, speed limit 3 is enabled by this status code.

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Status Code Troubleshooting Tables

2200 SRM 697

Status Code

Description

Memory Recall

Circuit

-92

Right traction motor temperature too high.

No

Traction and Pump

Symptom Status code flashes on and off.

Maximum travel speed is reduced.

Possible Causes and Test Procedures • Right traction motor is too hot.

Allow right traction motor to cool.

If problem recurs, determine reason for overheating traction motor and correct.

• P15 is shorted to battery negative.

Locate and repair short.

• Right traction motor temperature sensor is shorted or defective.

Replace temperature sensor.

• Defective lift pump controller.

(SR transistor-controlled lift pump only.)

Replace the lift pump controller.

• Defective sensor interface/contactor driver module.

(Contactor-controlled lift pump only.)

Replace the sensor interface/contactor driver module.

NOTE: Function 13, speed limit 3 is enabled by this status code.

48

Cause This status code is displayed when the voltage at terminal P15 of the SR lift pump controller or the sensor interface/contactor driver module is at zero volts.

2200 SRM 697

Status Code Troubleshooting Tables

Status Code

Description

Memory Recall

Circuit

-93

Power steering motor brushes are worn.

No

Traction and Pump

Symptom Status code flashes on and off.

Possible Causes and Test Procedures • Power steering motor brushes are worn.

A sensor has closed to battery positive.

Replace the power steering motor brushes.

• P3 and/or P4 is shorted to battery positive.

Locate and repair the short.

• A power steering motor brush wear sensor is shorted or defective.

Locate and repair the shorted sensor lead or replace the power steering motor brushes.

• Defective lift pump controller.

(SR transistor-controlled lift pump only.)

Replace the lift pump controller.

• Defective sensor interface/contactor driver module.

(Contactor-controlled lift pump only.)

Replace the sensor interface/contactor driver module.

NOTE: Status code 93 is only checked when a neutral signal is present (open start switch or open forward and reverse switches). The status code is then displayed when the controller is returned to the run mode.

Cause This status code is displayed when the voltage at terminal P3 and/or terminal P4 of the SR lift pump controller or the sensor interface/contactor driver module is at battery volts.

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Status Code Troubleshooting Tables

2200 SRM 697

Status Code

Description

Memory Recall

Circuit

-94

Left or right traction motor brushes are worn.

No

Traction and Pump

Symptom Status code flashes on and off.

Possible Causes and Test Procedures • Left or right traction motor brushes are worn.

A sensor has closed to battery positive.

Replace the traction motor brushes.

• P5 and/or P6 is shorted to battery positive.

Locate and repair the short.

• A traction motor brush wear sensor is shorted or defective.

Locate and repair the shorted sensor lead or replace the traction motor brushes.

• Defective pump controller.

(SR transistor-controlled lift pump only.)

Replace the pump controller.

• Defective sensor interface/contactor driver module.

(Contactor-controlled lift pump only.)

Replace the sensor interface/contactor driver module.

NOTE: Status code 94 is only checked when a neutral signal is present (open start switch or open forward and reverse switches). The status code is then displayed when the controller is returned to the run mode.

50

Cause This status code is displayed when the voltage at terminal P5 and/or terminal P6 of the SR lift pump controller or the sensor interface/contactor driver module is at battery volts.

2200 SRM 697

Status Code Troubleshooting Tables

Status Code

Description

Memory Recall

Circuit

-95

Lift pump motor brushes are worn.

No

Traction and Pump

Symptom Status code flashes on and off.

Possible Causes and Test Procedures • Lift pump motor brushes are worn.

A sensor has closed to battery positive.

Replace the traction motor brushes.

• P8 and/or P9 is shorted to battery positive.

Locate and repair the short.

• A lift pump motor brush wear sensor is shorted or defective.

Locate and repair the shorted sensor lead or replace the traction motor brushes.

• Defective pump controller.

(SR transistor-controlled lift pump only.)

Replace the pump controller.

• Defective sensor interface/contactor driver module.

(Contactor-controlled lift pump only.)

Replace the sensor interface/contactor driver module.

NOTE: Status code 95 is only checked when a neutral signal is present (open start switch or open forward and reverse switches). The status code is then displayed when the controller is returned to the run mode.

Cause This status code is displayed when the voltage at terminal P8 and/or terminal P9 of the SR lift pump controller or the sensor interface/contactor driver module is at battery volts.

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Status Code Troubleshooting Tables

2200 SRM 697

Status Code

Description

Memory Recall

Circuit

-99

Maintenance Alert and Speed Limit.

No

Traction

Symptom Status code is displayed for 4 seconds when the key switch is first turned on.

Maximum travel speed is reduced.

Possible Causes and Test Procedures • Status code -99 is displayed when the normal hourmeter reading exceeds the programmed maintenance alert hours setting selected by the user.

Maintenance Code Hourmeter, Functions 19 and 20, are programmed with the handset and command the display of status code -99.

• User should perform desired maintenance function.

Reset maintenance alert hourmeter after maintenance is performed.

NOTE: Program Functions 19 and 20 to a value above 99 to disable the maintenance alert and speed limit feature.

Cause This status code is displayed when the normal hourmeter reading exceeds the maintenance alert hours setting for the truck.

NOTE: Function 13, speed limit 3 is enabled by this status code.

Status Code

Description

Memory Recall

Circuit

-117

"Controller Type" selection is invalid.

No

Pump

Symptom Lift and auxiliary hydraulic functions are disabled or operate at a reduced rate.

Possible Causes and Test Procedures • Invalid "controller type" selection.

Check the setting of Function 17. Adjust Function 17 to the value listed in Table 10.

Cause This status code is displayed when the "controller type" selection value is set to an invalid number.

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2200 SRM 697

Status Code Troubleshooting Tables

Status Code

Description

Memory Recall

Circuit

-127

Controller internal power supply is less than 10 volts.

Yes

Pump

Symptom Lift pump will not operate.

Possible Causes and Test Procedures • Discharged battery.

Check battery to ensure proper state of charge.

• Loose connection at P1.

Ensure the wire connection at P1 is tight.

• Defective lift pump controller.

Replace lift pump controller.

Cause This status code is displayed when the controller’s internal power supply is less than 10 volts.

Status Code

Description

Memory Recall

Circuit

-141

Lift pump controller overtemperature.

No

Pump

Symptom Lift and auxiliary hydraulic functions are disabled or operate at a reduced rate.

Possible Causes and Test Procedures • Controller is in thermal cutback.

[Controller heat sink (metal mounting base) temperature is in excess of 60 C (140 F).]

Allow controller to cool; status code should disappear.

• Internal thermal protector has failed.

Measure the controller heat sink (metal mounting base) temperature during thermal cutback. Heat sink temperatures less than 60 C (140 F) during thermal cutback indicate a faulty thermal protector.

Replace lift pump controller.

Cause This status code is displayed when the voltage at the internal thermal protector is greater than 0.8 volt.

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Status Code Troubleshooting Tables

2200 SRM 697

Status Code

Description

Memory Recall

Circuit

-142

Pump controller motor current sensor input is missing.

No

Pump

Symptom Lift and auxiliary hydraulic functions are disabled.

Possible Causes and Test Procedures • Defective lift pump controller.

Replace lift pump controller.

Cause This status code is displayed when the voltage at the lift pump controller internal current sensor is greater than 0.1 volt with no current flowing in the motor circuit.

54

2200 SRM 697

Status Code Troubleshooting Tables

Status Code

Description

Memory Recall

Circuit

-143

Pump controller motor current sensor input is too low.

No

Pump

Symptom Lift and auxiliary hydraulic functions are disabled.

Possible Causes and Test Procedures • Defective lift pump controller.

Replace lift pump controller.

Cause This status code is displayed when the voltage at the lift pump controller internal current sensor is greater than 0.1 volt with no current flowing in the motor circuit.

Status Code

Description

Memory Recall

Circuit

-144

Power transistor (Q1) did not turn off properly.

Yes

Pump

Symptom Lift pump motor runs continuously.

Possible Causes and Test Procedures • Defective lift pump controller.

Replace lift pump controller.

Cause This status code is displayed when, during pump controller operation, the transistor fails to turn off.

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Status Code Troubleshooting Tables

2200 SRM 697

Status Code

Description

Memory Recall

Circuit

-145

Power transistor (Q1) did not turn on properly.

Yes

Pump

Symptom Lift and auxiliary hydraulic functions are disabled.

Possible Causes and Test Procedures • Defective lift pump controller.

Replace lift pump controller.

Cause This status code is displayed when, during pump controller operation, the transistor fails to turn on.

Status Code

Description

Memory Recall

Circuit

-146

"Look Ahead" test for A1 volts less than 12 percent of battery voltage.

Yes

Pump

Symptom Lift and auxiliary hydraulic functions are disabled.

Possible Causes and Test Procedures • Check for short circuit from the motor armature to the frame of the lift truck.

• Defective lift pump controller.

Replace lift pump controller.

Cause This status code is displayed when the voltage at A2 is less than 12 percent of battery voltage.

56

2200 SRM 697

Status Code Troubleshooting Tables

Status Code

Description

Memory Recall

Circuit

-151

Capacitor volts are low before the line contactor closes (internal controller function during precharge).

No

Pump

Symptom Lift and auxiliary hydraulic functions are disabled.

Controller capacitor does not precharge.

Line contactor may not close.

Possible Causes and Test Procedures • Failed key switch fuse.

Replace key switch fuse.

• Open key switch circuit.

Repair key switch circuit.

• Defective lift pump controller.

Replace lift pump controller.

• Accessory or component other than controllers connected to load side of line contactor.

Verify that the traction and lift pump controllers are the only components on the load side of the line contactor.

NOTE: Repeated charging/discharging of the capacitors during troubleshooting can cause status code 151.

Cause This status code is displayed during "key on" when the internal capacitor voltage is less than 85 percent of battery voltage at initial key switch on.

Status Code

Description

Memory Recall

Circuit

-157

Controller motor current sensor input voltage polarity check.

No

Pump

Symptom Lift and auxiliary hydraulic functions are disabled.

Possible Causes and Test Procedures • Defective lift pump controller.

Replace lift pump controller.

Cause This status code is displayed when the voltage input to the internal motor current sensor is of the wrong polarity.

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Status Code Troubleshooting Tables

2200 SRM 697

Status Code

Description

Memory Recall

Circuit

-180

Controller capacitor charge is less than 14 volts.

No

Pump

Symptom Lift and auxiliary hydraulic functions are disabled.

Possible Causes and Test Procedures • Line and auxiliary hydraulic functions are disabled.

Check power connection from battery positive to the line contactor.

Check for an open fuse element.

Check for dirty contactor tips.

Cause This status code is displayed when the voltage at P1 is less than 14 volts. This occurs typically in the run mode of operation.

Status Code

Description

Memory Recall

Circuit

-181

Battery voltage is less than 14 volts.

No

Pump

Symptom Lift and auxiliary hydraulic functions are disabled.

Possible Causes and Test Procedures • Line contactor opened up during the run mode.

Check power connection from battery positive to the line contactor.

Check for an open fuse element.

Check for dirty contactor tips.

Verify that there are no traction controller faults causing the line contactor to open during the run mode.

Cause This status code is displayed when the voltage measured at P1 is less than 14 volts.

58

2200 SRM 697

SX/SR Handset Instructions

SX/SR Handset Instructions GENERAL FEATURES The GE handset is a multifunctional tool used with the LX, ZX, SX, and SR series GE solid-state controllers. See Figure 11. The handset consists of a light-emitting diode (LED) display and a keyboard for data entry. The handset is used for viewing, adjusting, and storing controller function settings (values) and for accessing status codes.

NOTE: The handset is the same for all GE controllers; however, the cable will change between some control types.

NOTE: Controllers can be programmed prior to installation using a 24-VDC power supply. See Figure 12 for instructions on connecting the 24-VDC power supply.

See the section Troubleshooting and Adjustments With a Computer 2200 SRM 597 for information on the use of a PC to troubleshoot and adjust the controllers.

The following outlines the procedures for viewing, adjusting, and storing controller function settings (values) and for accessing status codes.

Figure 11. LX/ZX/SX/SR Handset

59

SX/SR Handset Instructions

Figure 12. Connecting a Remote Power Supply to Controller

60

2200 SRM 697

2200 SRM 697

CONNECTING THE HANDSET WARNING To avoid injury, perform the following steps before performing any troubleshooting, adjustments, or connecting or disconnecting of a handset or PC: 1. Block the lift truck so that the drive wheels are off the floor. See the section Periodic Maintenance 8000 SRM 699 or 8000 SRM 702. Refer to How to Put Lift Truck on Blocks.

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

3. Discharge the capacitors in the controllers by connecting a 200-ohm, 2-watt resistor across the controller’s POS and NEG terminals (outer two power cable terminals). See Figure 9. 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.

SX/SR Handset Instructions

STARTUP SEQUENCE NOTE: The term "push" means to depress key for approximately 1 second.

After installing the handset, plug the battery in and turn the key switch ON. Figure 14 shows the startup display sequence that will occur.

At the transistor controller, unplug the blank from the PY plug and plug in the handset. See Figure 13.

1. PY PLUG Figure 13. PY Plug Location NOTE: The lift truck can be operated with the handset connected; however, the adjustment knob must be set fully clockwise to ensure the controller operates at top speed.

NOTE: The plug cap or blank covering the PY plug on the controller contains internal jumpers. The plug cap must be replaced after unplugging the handset for normal lift truck operation.

Figure 14. Handset Startup Sequence

61

SX/SR Handset Instructions

SETUP MODE With the handset connected, follow Figure 15 to store or change function values.

2200 SRM 697

WARNING NEVER attempt to adjust any of the function values without using the procedures and values given in this section. Failure to follow these instructions can cause personal injury or property damage.

NOTE: The term "push" means to depress key for approximately 1 second.

NOTE: To check the value of a function, push the ESC key after selecting the function.

• Functions 1-15 are selected by pushing keys 1-15.

• Functions 16-30 are selected by pushing the CONT key and keys 1-15.

• Functions 48-62 are selected by closing the seat switch and pushing the CONT key and keys 1-15.

• Function 63 is selected by closing the seat switch and pushing the CONT and ESC keys.

To exit the setup mode, turn the key switch to the OFF position and push the ESC key for at least 1 second. The hourmeter reading should be displayed, and then after a few seconds, the display should go blank. Be sure to replace the PY plug blank once the handset is disconnected.

Figure 15. Handset Setup Mode

62

2200 SRM 697

STORED STATUS CODE MODE The SX/SR family of controllers furnishes a function register that contains the last 16 stored status codes that shut down lift truck operation (a PMT-type fault that is reset by cycling the key switch) and the battery state-of-charge reading at the time the fault occurred. See Figure 16. The first of the 16 status codes will be overwritten each time a new status code occurs. This stored status code register can be cleared from memory by using the handset.

SX/SR Handset Instructions NOTE: The term "push" means to depress key for approximately 1 second.

To exit the stored status code mode, hold down the CONT key. The display will scroll through the 16 stored status codes, battery state of charge, and hourmeter readings and then go blank.

CLEARING THE STORED STATUS CODES Stored status codes may be cleared one at a time by pushing the ESC key after the hourmeter reading is displayed. See Figure 16.

All stored status codes may be cleared by using the following procedure.

1. Access the first stored status code. See Figure 16.

2. While the first stored status code is being displayed, push and hold the CONT and ESC keys.

3. Hold the CONT and ESC keys depressed while the display scrolls through the 16 stored status code registers.

4. When the display goes blank, release the ESC key (continue to hold down the CONT key).

5. The display will scroll through the 16 stored status code registers again and then go blank.

6. Reset function 28 to 0 to ensure that the next status code is stored in the first register. Refer to Figure 15.

RESTARTING LIFT TRUCK If the lift truck does not operate after the handset is disconnected, the program in use may not have been exited properly. To correct this, disconnect the battery and discharge the capacitors using the proper procedure. See WARNING in Connecting the Handset. After discharging the capacitors, connect the battery and restart the truck using the normal procedure.

Figure 16. Accessing Stored Status Codes With Handset

63

SX Traction Controller Function Descriptions

2200 SRM 697

SX Traction Controller Function Descriptions WARNING NEVER attempt to adjust any of the function values without using the procedures and values given in this section. Failure to follow these instructions can cause personal injury or property damage.

WARNING Changing a function value will affect lift truck performance and operation. If function values are changed, make sure all operators of the lift truck know that the truck can now operate differently. Failure to inform all operators can cause personal injury or property damage.

WARNING Each function of each motor controller has a range of setting numbers (minimum/maximum values) so the motor controller can be used on different models of lift trucks. This variation is needed for lift trucks of different sizes and operating voltages. Adjustment of a function to the wrong value for your lift truck model can cause the truck to operate differently than normal. This different operation of the truck and failure to follow these instructions can cause injury or damage to the lift truck. Do not set a function value outside of the recommended minimum/maximum range for your model lift truck. See Table 7, Table 8, and Table 9 for the values for your lift truck.

CAUTION The ranges and values given in the following function descriptions are the ranges and the minimum and maximum values for the MOTOR CONTROLLER. The motor controller can be used on different models of lift trucks. Your lift truck may have specific settings or a different range of settings. Always refer to Table 7, Table 8, and Table 9 for the correct factory values and the range of allowable settings for your lift truck.

64

Function 01 Auto Regen Cancel Speed (Push 1)

WARNING Function 01 is not normally adjusted in the field. Adjusting Function 01 between the minimum and maximum values will not alter lift truck performance.

This setting adjusts the speed, below which the auto regen feature will cancel.

Function 02 Creep Speed (Push 2) This function allows the adjustment of the creep speed (controller "on time") of the lift truck. Creep speed can be adjusted when an accelerator input voltage between 3.3 and 3.9 volts is provided to the controller or when an accelerator resistance value between 6.0K and 4.0K ohms is provided to the controller.

Minimum Maximum Controller On Time On Time Set Range 2%

15%

0 to 255

Resolution (per set unit) 0.05%

Example: Function 02 set to 20 equals 3% on time.

(20 × 0.05%) + 2% = 3% • Higher settings increase creep speed.

• Lower settings decrease creep speed.

2200 SRM 697

SX Traction Controller Function Descriptions

Function 03 Controlled Acceleration (Push 3)

Function 05 Plugging Current Limit (Push 5)

This function allows for the adjustment of the time it takes for the controller to accelerate to 100 percent applied battery voltage to the motor on hard acceleration.

NOTE: This controlled acceleration is in effect when the standard instrument panel is used.

Minimum Time

Maximum Time

Controller Set Range

Resolution (per set unit)

0.025 sec

6.3 secs

0 to 255

0.025 sec

Example: Function 03 set at 20 equals 0.5 second.

(20 × 0.025 sec) + 0.025 sec = 0.5 sec • Higher settings provide slower acceleration.

• Lower settings provide faster acceleration.

Function 04 Armature Current Limit (Push 4) This function allows for the adjustment of the armature current limit of the controller. The rating of the controller will determine the range of adjustment for this function. See Figure 17 for the current limit curves. See Table 7, Table 8, and Table 9 for the values for your lift truck.

Minimum Current

Maximum Current

Controller Set Range

Resolution (per set unit)

*

*

0 to 255

-

See Figure 17 for the current limit curves.

See Table 7, Table 8, and Table 9 for recommended values.

• Higher settings increase armature current limit.

• Lower settings decrease armature current limit.

WARNING Plug settings outside of the recommended values can cause damage to the traction controller system or traction motor. See Table 7, Table 8, and Table 9 for recommended values.

This function allows for the adjustment of the plugging distance of the lift truck.

NOTE: Conventional plug braking only occurs when the steer tire is at an angle of 65 degrees or greater.

NOTE: Regenerative braking to zero speed is the normal method of slowing the truck when reversing direction. Regen braking current limit, Function 9, is adjusted to alter the stopping distance at steer angles less than 65 degrees.

Minimum Current

Maximum Current

Controller Set Range

Resolution (per set unit)

55 amps

455 amps

0 to 255

1.57 amps

Example: Function 05 set at 20 equals 86.4 amps.

(20 × 1.57 amps) + 55 amps = 86.4 amps • Higher settings decrease plugging distance.

• Lower settings increase plugging distance.

Function 06 FW Ratio (Push 6)

WARNING Function 06 is not normally adjusted in the field. Adjusting Function 06 between the minimum and maximum values will not alter lift truck performance.

This setting represents the ratio of field current to armature current.

NOTE: This FW ratio is in effect when the standard instrument panel is used.

65

SX Traction Controller Function Descriptions

Figure 17. Explanation of Current Limit Adjustments

66

2200 SRM 697

2200 SRM 697

SX Traction Controller Function Descriptions

Function 07 Minimum Field Current (Push 7)

Function 10 Field Current for Regenerative Braking (Push 10)

This function allows the adjustment of the field weakening level to set the top speed of the motor.

Minimum Current

Maximum Current

Controller Set Range

Resolution (per set unit)

0 amps

40 amps

51 to 255

0.185 amp

Example: Function 07 set at 71 equals 3.7 amps.

(71

51) × 0.185 amp = 3.7 amps

• Higher settings can decrease speed.

• Lower settings can increase speed.

NOTE: Settings less than 51 will result in 0 amps.

Function 08 Maximum Field Current (Push 8)

WARNING Function 08 is not normally adjusted in the field. Adjusting Function 08 between the minimum and maximum values will not alter lift truck performance.

This function adjusts the maximum field current to obtain the maximum torque of the motor.

Function 09 Regenerative Braking Current Limit (Push 9) This function adjusts the regen braking current limit.

Minimum Current

52 amps

Maximum Current

Controller Set Range

Resolution (per set unit)

468 amps

0 to 255

1.63 amps

Example: Function 09 set at 110 equals 231.3 amps.

(110 × 1.63 amps) + 52 amps = 231.3 amps • Higher settings decrease stopping distance.

• Lower settings increase stopping distance.

WARNING Function 10 is not normally adjusted in the field. Adjusting Function 10 between the minimum and maximum values will not alter lift truck performance.

This function adjusts the field current to be used during the regen braking mode.

Function 11 Turn Speed Limit (Push 11) This function allows for the adjustment of the maximum lift truck speed (maximum battery volts to the motor) available when the steer angle potentiometer signal indicates the steer angle is 32 degrees or greater.

Maximum Volts

Minimum Volts

Controller Set Range

Resolution (per set unit)

100%

0%

51 to 180

0.78%

Example: Function 11 set at 71 equals 84.4% B.V. 100%

[(71

51) × 0.78%] = 84.4%

• Higher settings decrease speed.

• Lower settings increase speed.

Function 12 Maximum Armature % On (Travel Speed Limit) (Push 12) Same as Function 11, always active to limit battery volts to the motor.

NOTE: This travel speed limit is in effect when the standard instrument panel is used.

Function 13 Speed Limit 3 (Push 13) This function allows for the adjustment of the maximum lift truck speed (maximum battery volts to the motor) available when speed limit 3 (SL3) is enabled.

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SX Traction Controller Function Descriptions SL3 is activated when fault code 29, 90, 91, 92, or 99 are present.

Function 14 Internal Resistance Compensation (Push 14)

2200 SRM 697 Function 15 Battery Volts (Push 15)

WARNING

This function is used when the internal battery discharge indicator feature is utilized. Adjustment of this function will improve the accuracy of the BDI.

Function 15 is not normally adjusted in the field. Adjusting Function 15 between the minimum and maximum values will not alter lift truck performance.

Use the specific gravity of the battery to determine if the internal battery discharge indicator feature is accurately reflecting battery condition.

This function allows for the adjustment of voltage range for controllers equipped with the battery discharge indicator function.

1. Remove the battery from service when the battery discharge gauge shows empty (discharged).

The battery discharge indicator considers empty to be the point when the gauge first shows the last red LED illuminated but not blinking.

Factory Values - Function 15

NOTE: The lift interrupt point may be used as a measuring point for empty, but it is not as accurate.

NEVER discharge a battery below a specific gravity of 1.130. The battery can have permanent damage if discharged below 1.130.

2. Follow the battery manufacturer’s instructions to allow ample time for the battery to stabilize (if possible).

3. Measure the specific gravity of at least several cells of the battery and compare the average specific gravity to the chart below.

Battery Specific Gravity Battery Gauge Shows Empty*

At Lift Interrupt

1.150

1.140

*Battery discharge indicator gauge shows the last red LED illuminated but not blinking.

• Higher settings increase battery S.G. at lift interrupt.

• Lower settings decrease battery S.G. at lift interrupt.

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Left Traction Controller

36/48 volts with BDI

186

Right Traction Controller

No BDI

255

NOTE: The left traction controller is the primary controller and it controls the BDI feature. The left controller for a dual-motor proportioning system will be set differently than the right controller. See Table 7, Table 8, and Table 9 for additional information.

Controller Set Range - Function 15 Battery Volts

Set Units

24 volts

Between 0 and 31

36 volts

Between 32 and 44

48 volts

Between 45 and 69

72 volts

Between 70 and 80

80 volts

Between 81 and 183

36/48 volts

Between 184 and 250

No BDI feature

Between 251 and 255

NOTE: The following functions have function numbers larger than the numbers on the handset keyboard. To access these functions, push the CONT key and the number shown in the following instructions at the same time.

2200 SRM 697

SX Traction Controller Function Descriptions

NOTE: The seat switch must be open to access Functions 16 to 28.

Function 16 Pedal Position Plug (Push CONT 1)

Factory Values - Function 17

This function will allow the adjustment of the pedal position plug range. Pedal position will reduce the plugging current to the current value set by this function as the accelerator is returned to the creep speed position. Maximum plug current is obtained with the accelerator in the top speed position.

Minimum Current

55 amps

This function allows for the selection of the controller type used for your lift truck’s application. The values listed below show the setting required for proper lift truck operation.

Maximum Current

Controller Set Range

Resolution (per set unit)

455 amps

0 to 255

1.57 amps

Example: Function 16 set at 20 equals 84.6 amps.

(20 × 1.57 amps) + 55 amps = 84.6 amps • Higher settings decrease plugging distance.

• Lower settings increase plugging distance.

To disable the pedal position plug function, adjust Function 16, Pedal Position Plug, to the same current value as Function 5, Plugging Current Limit.

Example: If Function 5, Plugging Current Limit, is set at 350 amps, then set Function 16, Pedal Position Plug, to 350 amps. With this setting, pedal position will have no effect on plugging distance.

NOTE: Lift trucks equipped with regenerative braking will vary the regen current with pedal position.

However, minimum regen current is fixed at 50 amps. The pedal position will vary regen current between 50 amps and the maximum value of regen current set by Function 9.

Function 17 "Controller Type" Selection (Push CONT 2)

Left Traction Controller

57

Right Traction Controller

121

NOTE: The left traction controller is the primary controller. The left controller for a dual-motor proportioning system will be set differently than the right controller. See Table 7, Table 8, and Table 9 for additional information.

Function 18 Steer Pump Time Delay (Push CONT 3) This function adjusts the steer pump contactor time delay. The power steering contactor will de-energize (open) after the seat switch remains open for a period in excess of the programmed steer pump time delay.

NOTE: The power steering contactor is initially energized when the seat switch is closed and the key switch is turned to the ON position. The power steering contactor will de-energize (open) immediately if the key switch opens.

Minimum Time

Maximum Time

Controller Set Range

Resolution (per set unit)

1.5 secs

65 secs

0 to 128

0.5 sec

Example: Function 18 set at 20 equals 11.5 seconds.

(20 × 0.5 sec) + 1.5 secs = 11.5 secs • Higher settings provide a longer delay.

• Lower settings provide a shorter delay.

WARNING Function 17 is not normally adjusted in the field. Adjusting Function 17 between the minimum and maximum values will not alter lift truck performance.

69

SX Traction Controller Function Descriptions

2200 SRM 697

Function 19 Maintenance Code Tens and Units Hours Set (Push CONT 4)

NOTE: The maintenance code alert/speed reduction can be disabled by setting both Function 19 and Function 20 to values above 99.

This function allows for the adjustment of the tens and units hours of the maintenance code activation time.

Function 21 Auto Regen Braking Current Limit (Push CONT 6)

Minimum Setting

00

Maximum Setting

Controller Set Range

Resolution (per set unit)

99

0 to 99

1 Hour

Example: Function 19 set at 50 equals XX50 hours, where XX is the programmed value of Function 20.

NOTE: Speed limit 3 is enabled once the set hours (as programmed by Functions 19 and 20) are reached.

NOTE: The maintenance code alert/speed reduction can be disabled by setting Function 19 and Function 20 to values above 99.

Function 20 Maintenance Code Thousands and Hundreds Hours Set (Push CONT 5) This function allows for the adjustment of the thousands and hundreds hours of the maintenance code activation time.

Minimum Setting

00

Maximum Setting

Controller Set Range

Resolution (per set unit)

99

0 to 99

1 Hour

Example: Function 20 set at 50 equals 50XX hours, where XX is the programmed value of Function 19.

NOTE: Speed Limit 3 is enabled once the set hours (as programmed by Functions 19 and 20) are reached.

70

This function allows for the adjustment of the auto regen braking current limit.

A

[(B

51) × 3.25] = Function 21 (amps)

A = Function 9 (amps) B = Setting of Function 21 Example: A = Function 9 amps = (110 × 1.63 amps) + 52 = 231.3 amps B = Function 21 setting = 60 231.3 amps [(60 51) × 3.25] = 202.5 amps • Higher settings increase stopping distance.

• Lower settings decrease stopping distance.

NOTE: Settings greater than 143 disable the auto regen braking feature.

Function 23 Error Compensation (Push CONT 8)

WARNING Function 23 is not normally adjusted in the field. Adjusting Function 23 between the minimum and maximum values will not alter lift truck performance.

The error compensation setting is adjusted by Function 23. This function is used to reduce the ripple in field current due to the interaction between motor field design and the digital field current regulation circuit. The value for this function is defined by the traction motor controller manufacturer.

NOTE: Function 23 must be set at 6.

2200 SRM 697 Function 24 FW Start (Push CONT 9)

WARNING Function 24 is not normally adjusted in the field. Adjusting Function 24 between the minimum and maximum values will not alter lift truck performance.

This function allows for setting the armature current at which minimum field current will achieved.

NOTE: This FW start is in effect when the standard instrument panel is used.

Function 25 Monitor (Push CONT 10)

WARNING Function 25 is not normally adjusted in the field. Adjusting Function 25 between the minimum and maximum values will not alter lift truck performance.

See the section Electrical System 2200 SRM 698 for the adjustment procedures for the steer angle potentiometer. Refer to Steer Angle Potentiometer, Adjustment, Handset Method.

This function allows the monitoring of certain controller functions by looking directly at the RAM of the microprocessor. Because absolute memory locations need to be known, the value of this function should not be changed without detailed instructions from the factory.

Function 26 Base Ratio (Push CONT 11)

WARNING Function 26 is not normally adjusted in the field. Adjusting Function 26 between the minimum and maximum values will not alter lift truck performance.

This function sets the ratio between armature and field current when operating below the maximum field current and above the Field Weakening Start point. The setting represents the quantity of field current changed for each 1 amp of armature current changed.

SX Traction Controller Function Descriptions Function 28 Stored Status Code Count Pointer (Push CONT 13) This register contains a coded number that indicates the location of the last stored status code. These stored status codes have caused a PMT controller shutdown and/or disruption of normal lift truck operation.

Function 28 should be set to 0 if the stored status codes are cleared (erased) using a handset. If stored status codes are cleared using a PC, Function 28 is automatically set to 0.

Refer to SX/SR Handset Instructions, Clearing the Stored Status Codes for instructions on clearing the stored status codes and resetting Function 28 to 0.

NOTE: When scrolling the stored status code register, the register always starts at status code 1 and scrolls to status code 16. Refer to SX/SR Handset Instructions, Status Code Scrolling for additional information.

PREMIUM INSTRUMENT PANEL INTERACTIVE MODES NOTE: The following functions (Functions 48 through 62) are mode settings that are activated using the performance level push button on the premium instrument panel.

NOTE: Each function should be set using the correct logic. Refer to Table 4 for the correct adjustment logic and sequence guidelines.

NOTE: The following functions have function numbers larger than the numbers on the handset keyboard. To access these functions, push the CONT key and the number shown in the following instructions at the same time.

NOTE: The seat switch must be closed to access Function 48 and above.

Function 48 Mode 1 (Turtle) - Controlled Acceleration (Push CONT 1) This function allows for the adjustment of the time it takes for the controller to accelerate to 100 percent applied battery voltage to the motor on hard acceleration.

71

SX Traction Controller Function Descriptions

Minimum Time

Maximum Time

Controller Set Range

Resolution (per set unit)

0.025 sec

6.3 secs

0 to 255

0.025 sec

Example: Function 48 set at 20 equals 0.5 second.

(20 × 0.025 sec) + 0.025 sec = 0.5 sec • Higher settings provide slower acceleration.

• Lower settings provide faster acceleration.

NOTE: This controlled acceleration is in effect when mode 1 is selected on the premium instrument panel.

Function 49 Mode 1 (Turtle) FW Start (Push CONT 2)

WARNING Function 49 is not normally adjusted in the field. Adjusting Function 49 between the minimum and maximum values will not alter lift truck performance.

This function allows for setting the armature current at which minimum field current is achieved.

NOTE: This FW start is in effect when mode 1 is selected on the premium instrument panel.

Function 50 Mode 1 (Turtle) - FW Ratio (Push CONT 3)

WARNING Function 50 is not normally adjusted in the field. Adjusting Function 50 between the minimum and maximum values will not alter lift truck performance.

This function sets the ratio between armature and field current when making the transition from minimum field to maximum field current. The setting represents the quantity of field current changed for each 1 amp of armature current changed.

NOTE: This FW ratio is in effect when mode 1 is selected on the premium instrument panel.

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2200 SRM 697 Function 51 Mode 1 (Turtle) - Maximum Armature Percent On (Mode 1 - Travel Speed Limit) (Push CONT 4) This function allows for the adjustment of the speed limit (maximum battery volts to the motor) when the SL1 input signal is received by the controller.

Maximum Volts

Minimum Volts

Controller Set Range

Resolution (per set unit)

100%

0%

51 to 180

0.78%

Example: Function 11 set at 71 equals 84.4% B.V. 100%

[(71

51) × 0.78%] = 84.4%

• Higher settings decrease speed.

• Lower settings increase speed.

NOTE: This travel speed limit is in effect when mode 1 is selected on the premium instrument panel.

Function 52 Mode 2 - Controlled Acceleration (Push CONT 5) Same as Function 48.

NOTE: This controlled acceleration is in effect when mode 2 is selected on the premium instrument panel.

Function 53 Mode 2 - FW Start (Push CONT 6)

WARNING Function 53 is not normally adjusted in the field. Adjusting Function 53 between the minimum and maximum values will not alter lift truck performance.

Same as Function 49.

NOTE: This FW start is in effect when mode 2 is selected on the premium instrument panel.

2200 SRM 697 Function 54 Mode 2 - FW Ratio (Push CONT 7)

WARNING

SX Traction Controller Function Descriptions Function 58 Mode 3 - FW Ratio (Push CONT 11)

WARNING

Function 54 is not normally adjusted in the field. Adjusting Function 54 between the minimum and maximum values will not alter lift truck performance.

Function 58 is not normally adjusted in the field. Adjusting Function 58 between the minimum and maximum values will not alter lift truck performance.

Same as Function 50.

Same as Function 50.

NOTE: This FW ratio is in effect when mode 2 is selected on the premium instrument panel.

NOTE: This FW ratio is in effect when mode 3 is selected on the premium instrument panel.

Function 55 Mode 2 - Maximum Armature Percent On (Mode 2 - Travel Speed Limit) (Push CONT 8)

Function 59 Mode 3 - Maximum Armature Percent On (Mode 3 - Travel Speed Limit) (Push CONT 12)

Same as Function 51.

Same as Function 51.

NOTE: This travel speed limit is in effect when mode 2 is selected on the premium instrument panel.

NOTE: This travel speed limit is in effect when mode 3 is selected on the premium instrument panel.

Function 56 Mode 3 - Controlled Acceleration (Push CONT 9)

Function 60 Mode 4 (Rabbit) - Controlled Acceleration (Push CONT 13)

Same as Function 48.

Same as Function 48.

NOTE: This controlled acceleration is in effect when mode 3 is selected on the premium instrument panel.

NOTE: This controlled acceleration is in effect when mode 4 is selected on the premium instrument panel.

Function 57 Mode 3 - FW Start (Push CONT 10)

Function 61 Mode 4 (Rabbit) - FW Start (Push CONT 14)

WARNING

WARNING

Function 57 is not normally adjusted in the field. Adjusting Function 57 between the minimum and maximum values will not alter lift truck performance.

Function 61 is not normally adjusted in the field. Adjusting Function 61 between the minimum and maximum values will not alter lift truck performance.

Same as Function 49.

Same as Function 49.

NOTE: This FW start is in effect when mode 3 is selected on the premium instrument panel.

NOTE: This FW start is in effect when mode 4 is selected on the premium instrument panel.

73

SR Pump Controller Function Descriptions Function 62 Mode 4 (Rabbit) - FW Ratio (Push CONT 15)

WARNING Function 62 is not normally adjusted in the field. Adjusting Function 62 between the minimum and maximum values will not alter lift truck performance.

Same as Function 50.

2200 SRM 697 NOTE: This FW ratio is in effect when mode 4 is selected on the premium instrument panel.

Function 63 Mode 4 - Maximum Armature Percent On (Mode 4 - Travel Speed Limit) (Push CONT ESC) Same as Function 51.

NOTE: This travel speed limit is in effect when mode 4 is selected on the premium instrument panel.

SR Pump Controller Function Descriptions WARNING NEVER attempt to adjust any of the function values without using the procedures and values given in this section. Failure to follow these instructions can cause personal injury or property damage.

WARNING Changing a function value will affect lift truck performance and operation. If function values are changed, make sure all operators of the lift truck know that the truck can now operate differently. Failure to inform all operators can cause personal injury or property damage.

WARNING Each function of each motor controller has a range of setting numbers (minimum/maximum values) so that the motor controller can be used on different models of lift trucks. This variation is needed for lift trucks of different sizes and operating voltages. Adjustment of function to the wrong value for your lift truck model can cause the truck to operate differently than normal. This different operation of the truck and failure to follow these instructions can cause injury or damage to the lift

74

truck. Do not set a function value outside of the recommended minimum/maximum range for your model lift truck. See Table 10 for the values for your lift truck.

CAUTION The ranges and values given in the following function descriptions are the ranges and the minimum and maximum values for the MOTOR CONTROLLER. The motor controller can be used on different models of lift trucks. Your lift truck may have specific settings or a different range of settings. Always refer to Table 10 for the correct factory values and the range of allowable settings for your lift truck.

Function 01 Stored Fault Code (Push 1) This function register contains the last status code that shut down lift truck operation (PMT-type fault that is reset by cycling the key switch). This status code will be overwritten each time a new fault occurs and can be cleared from memory by adjusting the value to zero. This register will be cleared when the battery is unplugged.

2200 SRM 697

SR Pump Controller Function Descriptions

Function 02 Internal Resistance Compensation Start (Push 2) This function allows for the adjustment of the current level at which the internal resistance compensation feature (Function 16) will take effect.

Minimum Level

0 amps

Maximum Level

Controller Set Range

Resolution (per set unit)

1325 amps

52 to 255

6.5 amps

Example: Function 02 set at 72 equals 130 amps.

(72

52) × 6.5 amps = 130 amps

• Higher settings = Function 16 at a higher current.

• Lower settings = Function 16 at a lower current.

Function 04 Current Limit (Push 4)

WARNING Function 04 is not normally adjusted in the field. Adjusting Function 04 between the minimum and maximum values will not alter lift truck performance.

This function sets the adjustment of the current limit of the controller. The rating of the controller will determine the range of adjustment for this function.

Minimum Current

Maximum Current

Controller Set Range

Resolution (per set unit)

*

*

255 to 255

-

*See Table 10 for recommended values.

Function 03 Controlled Acceleration (Push 3)

• Higher settings increase current limit.

• Lower settings decrease current limit.

This function allows for the adjustment of the time it takes for the controller to accelerate to 96 percent applied battery voltage to the motor on hard acceleration.

Minimum Time

Maximum Time

Controller Set Range

Resolution (per set unit)

0.1 sec

5.5 secs

0 to 255

0.021 sec

Example: Function 03 set at 20 equals 0.52 seconds.

(20 × 0.021 sec) + 0.1 sec = 0.52 sec • Higher settings provide slower acceleration.

• Lower settings provide faster acceleration.

NOTE: This controlled acceleration is in effect when the standard instrument panel is used.

Function 07 Internal Resistance Compensation Rate (Push 7) This function allows for the adjustment of the time it takes for the controller to add the internal resistance compensation voltage that is applied to the motor. This function will add 0.375 volt to the motor at the rate of time adjusted until the total internal resistance compensation voltage has been added.

NOTE: The internal resistance compensation voltage is set by Function 16, Speed/Torque Compensation.

Minimum Time

Maximum Time

Controller Set Range

Resolution (per set unit)

0.0015 sec

0.383 sec

0 to 255

0.0015 sec

Example: Function 07 set at 20 equals 0.032 seconds.

(20 × 0.0015 sec) + 0.0015 sec = 0.032 sec • Higher settings provide a slower compensation.

• Lower settings provide a faster compensation.

75

SR Pump Controller Function Descriptions For example, if you had selected 2.08 volts from Function 16 to be added to the motor, it would take 0.18 second to add a total of 2.08 volts.

(2.08 ÷ 0.375) × 0.032 = 0.18 second Function 11 Speed Limit 1 (SL1) (Push 11) This function allows for the adjustment of the speed limit (maximum battery volts to the motor) when the SL1 limit switch input signal is received by the controller. SL1 limit switch is a normally open switch connected to battery negative; the switch closing enables speed limit.

Minimum Volts

Maximum Volts

Controller Set Range

Resolution (per set unit)

0%

100%

0 to 255

0.375 volt

Example: Function 11 set at 50 equals 18.75 volts.

0.375 volt × 50 = 18.75 volts • Higher settings increase speed.

• Lower settings decrease speed.

2200 SRM 697 NOTE: Speed Limit 4 is not used on this model.

NOTE: The following functions have function numbers larger than the numbers on the handset keyboard. To access these functions. Push the CONT key and the number shown in the following instructions at the same time.

NOTE: The key switch must be in the OFF position to access Functions 16 to 28.

Function 16 Speed/Torque Compensation (Push CONT 1) This function is used to stabilize lift pump speed at heavy loads. The voltage selected will be added to the motor at each 100-amp increment, starting at the value set in Function 2. The voltage compensation selected will be added in increments of 0.375 volt until the entire voltage is added. For example, a setting of 2 will be added in 30 steps of 0.375 volt each, whereas a setting of 4 will be added in 15 steps of 0.375 volt each. See Table 6.

Table 6. Speed/Torque Compensation Setting

Voltage Drop

Setting

Voltage Drop

2

11.44

17

1.34

3

7.60

18

1.27

Same as Function 11 except using SL2 limit switch for input.

4

5.72

19

1.20

5

4.57

20

1.14

NOTE: This speed limit 2 is in effect when the standard instrument panel is used.

6

3.81

21

1.09

7

3.27

22

1.04

Function 13 Speed Limit 3 (SL3) (Push 13)

8

2.86

23

0.99

9

2.54

24

0.95

10

2.28

25

0.91

11

2.08

26

0.88

NOTE: This speed limit 3 is in effect when the standard instrument panel is used.

12

1.90

27

0.85

13

1.76

28

0.82

Function 14 Speed Limit 4 (SL4) (Push 14)

14

1.63

29

0.79

15

1.52

30

0.76

16

1.43

31

0.74

Function 12 Speed Limit 2 (SL2) (Push 12)

Same as Function 11 except using SL3 limit switch for input.

Same as Function 11 except using SL4 limit switch for input.

76

2200 SRM 697 Function 17 "Controller Type" Selection (Push CONT 2)

WARNING Function 17 is not normally adjusted in the field. Adjusting Function 17 between the minimum and maximum values will not alter lift truck performance.

This function allows for the selection of the controller type used for your lift truck’s application.

Refer to Table 10 for the factory value for your truck.

Function 28 Stored Status Code Count Pointer (Push CONT 13) This register contains a coded number that indicates the location of the last stored status code. These stored status codes have caused a PMT controller shutdown and/or disruption of normal lift truck operation.

Function 28 should be set to 0 if the stored status codes are cleared (erased) using a handset. If stored status codes are cleared using a PC, Function 28 is automatically set to 0.

Refer to SX/SR Handset Instructions, Clearing the Stored Status Codes for instructions on clearing the stored status codes and resetting Function 28 to 0.

NOTE: When scrolling the stored status code register, the register always starts at status code 1 and scrolls to status code 16. Refer to SX/SR Handset Instructions, Status Code Scrolling for additional information.

PREMIUM INSTRUMENT PANEL INTERACTIVE MODES NOTE: The following functions (Functions 48 through 62) are mode settings that are activated using the performance level push button on the premium instrument panel.

NOTE: Each function should be set using the correct logic. Refer to Table 5 for the correct adjustment logic and sequence guidelines.

NOTE: The following functions have function numbers larger than the numbers on the handset keyboard. To access these functions, push the CONT key

SR Pump Controller Function Descriptions and the number shown in the following instructions at the same time.

NOTE: The key switch must be in the ON position to access Functions 48 to 62.

Function 48 Mode 1 (Turtle) - Controlled Acceleration (Push CONT 1) This function allows for the adjustment of the time it takes for the controller to accelerate to 96 percent applied battery voltage to the motor on hard acceleration.

Minimum Time

Maximum Time

Controller Set Range

Resolution (per set unit)

0.1 sec

5.5 secs

0 to 255

0.021 sec

Example: Function 48 set at 20 equals 0.52 second.

(20 × 0.021 sec) + 0.1 sec = 0.52 sec • Higher settings provide slower acceleration.

• Lower settings provide faster acceleration.

NOTE: This controlled acceleration is in effect when mode 1 is selected on the premium instrument panel.

Function 49 Mode 1 (Turtle) - Speed Limit 2 (SL2) (Push CONT 1) This function allows for the adjustment of the speed limit (maximum battery volts to the motor) when the SL2 limit switch input signal is received by the controller. SL2 limit switch is a normally open switch connected to battery negative; the switch closing enables speed limit.

Minimum Volts

Maximum Volts

Controller Set Range

Resolution (per set unit)

0%

100%

0 to 255

0.375 volt

Example: Function 50 set at 50 equals 18.75 volts.

50 × 0.375 volt = 18.75 volts • Higher settings increase speed.

• Lower settings decrease speed.

77

SR Pump Controller Function Descriptions NOTE: This speed limit 2 is in effect when mode 1 is selected on the premium instrument panel.

Function 50 Mode 1 (Turtle) - Speed Limit 3 (SL3) (Push CONT 3) This function allows for the adjustment of the speed limit (maximum battery volts to the motor) when the SL3 limit switch input signal is received by the controller. SL3 limit switch is a normally open switch connected to battery negative; the switch closing enables speed limit.

Minimum Volts

Maximum Volts

Controller Set Range

Resolution (per set unit)

0%

100%

0 to 255

0.375 volt

Example: Function 50 set at 50 equals 18.75 volts.

50 × 0.375 volt = 18.75 volts • Higher settings increase speed.

• Lower settings decrease speed.

NOTE: This speed limit 3 is in effect when mode 1 is selected on the premium instrument panel.

Function 52 Mode 2 - Controlled Acceleration (Push CONT 5) Same as Function 48.

NOTE: This controlled acceleration is in effect when mode 2 is selected on the premium instrument panel.

Function 53 Mode 2 - Speed Limit 2 (SL2) (Push CONT 6) Same as Function 49.

NOTE: This speed limit 2 is in effect when mode 2 is selected on the premium instrument panel.

Function 54 Mode 2 - Speed Limit 3 (SL3) (Push CONT 7) Same as Function 50.

NOTE: This speed limit 3 is in effect when mode 2 is selected on the premium instrument panel.

78

2200 SRM 697 Function 56 Mode 3 - Controlled Acceleration (Push CONT 9) Same as Function 48.

NOTE: This controlled acceleration is in effect when mode 3 is selected on the premium instrument panel.

Function 57 Mode 3 - Speed Limit 2 (SL2) (Push CONT 10) Same as Function 49.

NOTE: This speed limit 2 is in effect when mode 3 is selected on the premium instrument panel.

Function 58 Mode 3 - Speed Limit 3 (SL3) (Push CONT 11) Same as Function 50.

NOTE: This speed limit 3 is in effect when mode 3 is selected on the premium instrument panel.

Function 60 Mode 4 (Rabbit) - Controlled Acceleration (Push CONT 13) Same as Function 48.

NOTE: This controlled acceleration is in effect when mode 4 is selected on the premium instrument panel.

Function 61 Mode 4 (Rabbit) - Speed Limit 2 (SL2) (Push CONT 14) Same as Function 49.

NOTE: This speed limit 2 is in effect when mode 4 is selected on the premium instrument panel.

Function 62 Mode 4 (Rabbit) - Speed Limit 3 (SL3) (Push CONT 15) Same as Function 50.

NOTE: This speed limit 3 is in effect when mode 4 is selected on the premium instrument panel.

2200 SRM 697

SR Pump Controller Function Descriptions Table 7. Traction Controller Settings - Standard With Auto Regen Function

No.

Description

Setting Minimum

Factory

Maximum

1

Auto Regen Cancel Speed

17

18

19

2

Creep Speed

0

15

255

3

Controlled Acceleration

40

121

255

4

Armature Current Limit

0

255

255

5

Plugging Current Limit

0

100

105

6

FW Ratio

42

45

48

7

Minimum Field Current

0

51

80

8

Maximum Field Current

198

200

202

9

Regen Braking Current Limit

0

110

115

10

Regen Field Current

152

155

158

11

Turn Speed Limit

51

130

180

12

Maximum Armature Percent On

65

66

130

13

Speed Limit 3

51

130

180

14

Internal Resistance Compensation

2

8

29

Battery Volts - Left Controller (Primary)

184

186

250

Battery Volts - Right Controller

251

255

255

Pedal Position Plug

0

40

115

Controller Type - Left Controller (Primary)

55

57

59

Controller Type - Right Controller

119

121

123

15 16 17 18

Steer Pump Time Delay

0

25

128

19

Maintenance Code Hourmeter (×1)

0

255

255

20

Maintenance Code Hourmeter (×100)

0

255

255

21

Auto Regen Braking Current Limit

51

60

255

23

Error Compensation

6

6

6

24

FW Start

44

45

50

25

Monitor

0

0

0

NOTE: Left and right controller functions must be programmed to identical values except for Function 15 and Function 17.

79

SR Pump Controller Function Descriptions

2200 SRM 697

Table 7. Traction Controller Settings - Standard With Auto Regen (Continued) Function No.

Description

Setting Minimum

Factory

Maximum

26

Base Ratio

63

65

68

48

Mode 1 - Controlled Acceleration

40

141

255

49

Mode 1 - FW Start

44

45

48

50

Mode 1 - FW Ratio

42

45

48

51

Mode 1 - Maximum Armature Percent On

65

101

130

52

Mode 2 - Controlled Acceleration

40

121

255

53

Mode 2 - FW Start

44

45

50

54

Mode 2 - FW Ratio

42

45

48

55

Mode 2 - Maximum Armature Percent On

65

90

130

56

Mode 3 - Controlled Acceleration

40

121

255

57

Mode 3 - FW Start

44

45

50

58

Mode 3 - FW Ratio

42

45

48

59

Mode 3 - Maximum Armature Percent On

65

79

130

60

Mode 3 - Controlled Acceleration

40

121

255

61

Mode 4 - FW Start

44

45

50

62

Mode 4 - FW Ratio

42

45

48

63

Mode 4 - Maximum Armature Percent On

65

66

130

NOTE: Left and right controller functions must be programmed to identical values except for Function 15 and Function 17.

80

2200 SRM 697

SR Pump Controller Function Descriptions Table 8. Traction Controller Settings - Standard Without Auto Regen Function

No.

Description

Setting Minimum

Factory

Maximum

1

Auto Regen Cancel Speed

17

18

19

2

Creep Speed

0

15

255

3

Controlled Acceleration

40

121

255

4

Armature Current Limit

0

255

255

5

Plugging Current Limit

0

100

105

6

FW Ratio

42

45

48

7

Minimum Field Current

0

51

80

8

Maximum Field Current

198

200

202

9

Regen Braking Current Limit

0

110

115

10

Regen Field Current

152

155

158

11

Turn Speed Limit

51

130

180

12

Maximum Armature Percent On

65

66

130

13

Speed Limit 3

51

130

180

14

Internal Resistance Compensation

2

8

29

Battery Volts - Left Controller (Primary)

184

186

250

Battery Volts - Right Controller

251

255

255

Pedal Position Plug

0

40

115

Controller Type - Left Controller (Primary)

55

57

59

Controller Type - Right Controller

119

121

123

15 16 17 18

Steer Pump Time Delay

0

25

128

19

Maintenance Code Hourmeter (×1)

0

255

255

20

Maintenance Code Hourmeter (×100)

0

255

255

21

Auto Regen Braking Current Limit

51

255

255

23

Error Compensation

6

6

6

24

FW Start

44

45

50

25

Monitor

0

0

0

NOTE: Left and right controller functions must be programmed to identical values except for Function 15 and Function 17.

81

SR Pump Controller Function Descriptions

2200 SRM 697

Table 8. Traction Controller Settings - Standard Without Auto Regen (Continued) Function No.

Description

Setting Minimum

Factory

Maximum

26

Base Ratio

63

65

68

48

Mode 1 - Controlled Acceleration

40

141

255

49

Mode 1 - FW Start

44

45

48

50

Mode 1 - FW Ratio

42

45

48

51

Mode 1 - Maximum Armature Percent On

65

101

130

52

Mode 2 - Controlled Acceleration

40

121

255

53

Mode 2 - FW Start

44

45

50

54

Mode 2 - FW Ratio

42

45

48

55

Mode 2 - Maximum Armature Percent On

65

90

130

56

Mode 3 - Controlled Acceleration

40

121

255

57

Mode 3 - FW Start

44

45

50

58

Mode 3 - FW Ratio

42

45

48

59

Mode 3 - Maximum Armature Percent On

65

79

130

60

Mode 3 - Controlled Acceleration

40

121

255

61

Mode 4 - FW Start

44

45

50

62

Mode 4 - FW Ratio

42

45

48

63

Mode 4 - Maximum Armature Percent On

65

66

130

NOTE: Left and right controller functions must be programmed to identical values except for Function 15 and Function 17.

82

2200 SRM 697

SR Pump Controller Function Descriptions

Table 9. Traction Controller Settings - High Performance With Auto Regen Function No.

Description

Setting Minimum

Factory

Maximum

1

Auto Regen Cancel Speed

17

18

19

2

Creep Speed

0

15

255

3

Controlled Acceleration

40

81

255

4

Armature Current Limit

0

255

255

5

Plugging Current Limit

0

100

105

6

FW Ratio

42

45

48

7

Minimum Field Current

0

51

80

8

Maximum Field Current

198

200

202

9

Regen Braking Current Limit

0

110

115

10

Regen Field Current

152

155

158

11

Turn Speed Limit

51

130

180

12

Maximum Armature Percent On

65

66

130

13

Speed Limit 3

51

130

180

14

Internal Resistance Compensation

2

8

29

Battery Volts - Left Controller (Primary)

184

186

250

Battery Volts - Right Controller

251

255

255

Pedal Position Plug

0

40

115

Controller Type - Left Controller (Primary)

55

57

59

Controller Type - Right Controller

119

121

123

15 16 17 18

Steer Pump Time Delay

0

25

128

19

Maintenance Code Hourmeter (×1)

0

255

255

20

Maintenance Code Hourmeter (×100)

0

255

255

21

Auto Regen Braking Current Limit

51

60

255

23

Error Compensation

6

6

6

24

FW Start

44

45

50

25

Monitor

0

0

0

NOTE: Left and right controller functions must be programmed to identical values except for Function 15 and Function 17.

83

SR Pump Controller Function Descriptions

2200 SRM 697

Table 9. Traction Controller Settings - High Performance With Auto Regen (Continued) Function No.

Description

Setting Minimum

Factory

Maximum

26

Base Ratio

63

65

68

48

Mode 1 - Controlled Acceleration

40

141

255

49

Mode 1 - FW Start

44

45

50

50

Mode 1 - FW Ratio

42

45

48

51

Mode 1 - Maximum Armature Percent On

65

101

130

52

Mode 2 - Controlled Acceleration

40

121

255

53

Mode 2 - FW Start

44

45

50

54

Mode 2 - FW Ratio

42

45

48

55

Mode 2 - Maximum Armature Percent On

65

90

130

56

Mode 3 - Controlled Acceleration

40

101

255

57

Mode 3 - FW Start

44

45

50

58

Mode 3 - FW Ratio

42

45

48

59

Mode 3 - Maximum Armature Percent On

65

79

130

60

Mode 3 - Controlled Acceleration

40

81

255

61

Mode 4 - FW Start

44

45

50

62

Mode 4 - FW Ratio

42

45

48

63

Mode 4 - Maximum Armature Percent On

65

66

130

NOTE: Left and right controller functions must be programmed to identical values except for Function 15 and Function 17.

84

2200 SRM 697

SR Pump Controller Function Descriptions Table 10. Lift Pump Controller Settings Function

No.

Minimum

Factory

Maximum

0

0

255

1

Stored Fault Code

2

Internal Resistance Compensation Start

0

64

255

3

Controlled Acceleration

10

26

150

4

Current Limit

255

255

255

7

Internal Resistance Compensation Rate

0

15

255

11

Speed Limit 1 - Tilt, Auxiliary 1

30

50

70

12

Speed Limit 2 - Slow Lift, Auxiliary 2

30

65

70

13

Speed Limit 3 - Fast Lift

30

255

255

14

Speed Limit 4 (Not Used)

0

0

0

16

Internal Resistance Compensation

0

25

255

Controller Type - Without Internal Lift Interrupt Feature

45

50

53

Controller Type - With Internal Lift Interrupt Feature

63

65

71

48

Mode 1 - Controlled Acceleration

25

55

150

49

Mode 1 - Speed Limit 2 - Slow Lift, Auxiliary 2

30

65

70

50

Mode 1 - Speed Limit 3 - Fast Lift

30

84

255

52

Mode 2 - Controlled Acceleration

25

45

150

53

Mode 2 - Speed Limit 2 - Slow Lift, Auxiliary 2

30

65

70

54

Mode 2 - Speed Limit 3 - Fast Lift

30

96

155

56

Mode 3 - Controlled Acceleration

25

35

150

57

Mode 3 - Speed Limit 2 - Slow Lift, Auxiliary 2

30

65

70

58

Mode 3 - Speed Limit 3 - Fast Lift

30

108

255

60

Mode 4 - Controlled Acceleration

25

26

150

61

Mode 4 - Speed Limit 2 - Slow Lift, Auxiliary 2

30

65

70

62

Mode 4 - Speed Limit 3 - Fast Lift

30

255

255

17

1

Description 1

Setting

Any number other than zero can be read as a possible fault.

85

NOTES ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

86

TECHNICAL PUBLICATIONS 2200 SRM 697

9/03 (10/97) Printed in U.S.A.

67((5,1* 6<67(0 J30-40XMT 2 [H160]

PART NO. 1468297

1600 SRM 769

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR • When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks.

• Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit 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!

Steering System

Table of Contents

TABLE OF CONTENTS General ...............................................................................................................................................................

Operation............................................................................................................................................................

Steering Wheel and Column Assembly.............................................................................................................

Description .....................................................................................................................................................

Remove ...........................................................................................................................................................

Install .............................................................................................................................................................

Power Steering Pump and Motor ......................................................................................................................

Description .....................................................................................................................................................

Remove ...........................................................................................................................................................

Install .............................................................................................................................................................

Disassemble ...................................................................................................................................................

Assemble ........................................................................................................................................................

Steering Axle Components ................................................................................................................................

General ...........................................................................................................................................................

Wheel and Tire Assembly..............................................................................................................................

Remove.......................................................................................................................................................

Install .........................................................................................................................................................

Wheel Hub Assembly.....................................................................................................................................

Remove.......................................................................................................................................................

Install .........................................................................................................................................................

Steering Axle Assembly.................................................................................................................................

Remove.......................................................................................................................................................

Clean ..........................................................................................................................................................

Install .........................................................................................................................................................

Steering System Air Removal ...........................................................................................................................

Operation Check ................................................................................................................................................

Steering Pressure Check ...................................................................................................................................

Troubleshooting..................................................................................................................................................

1 1 2 2 2 5 6 6 6 8 8 9 10 10 10 10 10 10 10 11 11 11 12 12 14 14 15 15

This section is for the following models: J30-40XMT 2 [H160]

©2002 HYSTER COMPANY

i

1600 SRM 769

Operation

General The power steering system is a hydraulic system that does not have a mechanical connection between the steering wheel and the steering axle. The control of the steering is through a hydraulic circuit.

The hydraulic circuit for the power steering includes a common hydraulic tank that is used for both the steering and other hydraulic functions of the lift truck. The power steering pump is supplied by its own suction line. The power steering pump, located in the steering column, directs the hydraulic oil to the steering control unit when the steering wheel is turned.

The steering control unit is a rotary pump operated by the steering wheel. During the steering operation, the steering control unit controls the direction of flow and amount of oil that flows to the steering axle.

The steering cylinder actuates the steering linkage to move the steer wheel. Hydraulic oil returns from the steering cylinder to the steering control unit and then returns to the hydraulic tank. See Figure 4 and Figure 9.

An optional on-demand steering module is available.

When the on-demand steering module is furnished,

the steering pump motor does not operate unless the steering wheel is rotated. There is a delay between the last rotation of the steering wheel and the system shutting down. This delay keeps the system operating when the operator is not turning the steering wheel.

A gear on the shaft of the steering wheel drives a gear on the on-demand optical encoder when the steering wheel is turned. The optical encoder sends a signal to the activator. The activator completes the battery negative circuit for the steering contactor to energize the steering pump motor. Refer to the section Electrical System 2200 SRM 774.

If the steering pump does not operate, a check valve permits the steering control unit to control the steering system. The lift truck is difficult to steer when the steering pump is not operating, but the steering control unit can operate the steering cylinder and make steering possible. See the section Steering Housing and Steering Control Unit 1600 SRM 773 for information concerning the steering control unit.

Operation Turning the steering wheel actuates three main parts of the steering control unit: • Spool for the control section • Sleeve for the control section • Rotor in the metering section When the steering wheel is not moving, the spool and sleeve are held in the neutral (center) position by springs. During this time, oil flows freely through the steering control unit. The oil does not flow to the steering unit.

As the steering wheel is turned, the spool just begins to rotate. The springs try to move the sleeve to keep the neutral position between the spool and sleeve. However, the force necessary to turn the rotor is greater than the pressure of the springs. The springs begin to bend, letting the spool move a small amount within the sleeve. The spool stops moving when it touches the center pin. In this position, the holes in the sleeve and the spool are aligned. Oil coming into the control unit flows to the metering section.

More rotation of the steering wheel causes the spool to rotate the pin. This action causes the rotation of the sleeve and the rotor in the metering section. The oil then flows to one side of the steering unit. Hydraulic oil from the other side of the steering unit returns through the control section of the steering control unit.

When the steering wheel stops moving, the metering action in the metering section also stops. The neutral position springs return the sleeve to the neutral position. When this action occurs, the pressure stays in the steering cylinder to keep the steer wheels in position. Oil from the pump flows through the steering control unit to the tank or other parts of the system.

To return the steering wheel to the straight position, the steering wheel must be rotated in the opposite direction. The steering control unit will operate as described, but all parts will rotate in the opposite direction.

1

Steering Wheel and Column Assembly

1600 SRM 769

Steering Wheel and Column Assembly DESCRIPTION The upper end of the steering shaft has splines for the steering wheel. A large nut holds the steering wheel onto the steering shaft. The horn button is the cover for the center of the steering wheel. The lower end of the steering shaft has splines to engage the steering control unit. See Figure 1.

The steering column covers allow access to the optical encoder, steering control unit, key switch, horn switch, and direction switches.

The steering housing has mounts for the steering column and the steering control unit. The steering wheel is installed on the steering column. The housing is adjustable and is held in position by a latch.

The position of the housing can be changed for different operator requirements. The steering housing is also the mount for the control levers.

This section does not cover the instrument panel, key switch, or directional controls. Refer to the section SX/SR Transistor Motor Controllers and Handset 2200 SRM 774.

REMOVE NOTE: This procedure is for the removal of all components of the steering column assembly. It is not always necessary to remove all components for a repair procedure. Perform only those steps of the procedure necessary to remove the required component.

1. Disconnect battery connector. Move steering column to the most forward position. Remove steering column covers from steering column. See Figure 2.

2. Make an identification of the electric wires and disconnect them from key switch. If necessary, remove key switch from steering column cover.

WARNING The spring (23, Figure 2) used to retain the optical encoder has tension and can release with enough force to cause injury.

3. Remove optical encoder by releasing spring retaining encoder to steering column. Move unit and ribbon wire away from steering column.

1. STEERING WHEEL 2. STEERING COLUMN 3. STEERING CONTROL UNIT

4.

5.

6.

7.

8.

KNOB LATCH COVER COWL MOUNT

Figure 1. Steering Column

2

4. When a directional switch is used on the steering column instead of a MONOTROL® pedal, make an identification of electric wires and disconnect them from directional switches. See Figure 3.

Remove two shoulder bolts, spring washers, and nuts retaining directional switch bracket to steering column. Remove directional switches from bracket if necessary.

1600 SRM 769

Steering Wheel and Column Assembly

Figure 2. Steering Column Components

3

Steering Wheel and Column Assembly

1600 SRM 769 Legend for Figure 2

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

GROMMET UPPER COVER LOWER COVER SCREW KNOB-LATCH SCREW WASHER SPRING ROD SOCKET HEAD BOLT NUT

PLATE HEX HEAD BOLT LOCKWASHER SPRING SHAFT NUT HORN BUTTON STEERING WHEEL GEAR LATCH PIN COTTER PIN

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

33.

SPRING GEAR ENCODER HOUSING STEERING COLUMN HEX HEAD BOLT LOCKWASHER WASHER BRACKET STEERING CONTROL UNIT HORN CONTACT

5. Remove horn cover, snap ring, and base plate.

Loosen screws retaining horn wire leads to base plate. Remove large hex nut and remove steering wheel from shaft. A puller makes removal of steering wheel easier.

6. Remove two hex head bolts and washers retaining shift lever assembly to steering column and remove shift lever assembly. If necessary, disassemble shift lever assembly.

WARNING The hydraulic hoses MUST be connected to the correct ports and fittings, or the steering system will not operate as expected. This unexpected operation can cause damage or personal injury. Make sure the hoses are identified and connected correctly.

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SHIFT LEVER SCREW NUT PLUNGER CRANK CRANK LINK SHOULDER BOLT NUT SPRING WASHER BASE

12.

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20.

21.

HEX HEAD BOLT LOCKWASHER WASHER NUT SWITCH HEX HEAD BOLT LOCKWASHER WASHER PLATE WIRE HARNESS

Figure 3. Optional Directional Switch

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

4

7. Make an identification of the hydraulic hoses at the steering control unit so they can be connected correctly during assembly. Remove all mount clamps so the hoses will turn freely and not become twisted. Disconnect hydraulic hoses at the bottom of the steering control unit. Install plugs at all hose ports to prevent dirt from entering steering hydraulic system.

WARNING The spring (8, Figure 2) used to operate the latch for locking the steering column has tension and can release with enough force to cause injury.

8. Use a set of locking pliers and position them under washer and spring on rod between latch and steering column bracket. Carefully lift pliers high enough to compress spring and move rod out of the detent in the latch. Remove spring, washer, and rod from steering column.

Remove cotter pin and clevis pin retaining latch.

1600 SRM 769 If necessary, remove latch knob from latch by removing two screws.

9. Remove four hex head bolts retaining steering control unit to steering column bracket. Remove steering column from steering control unit and steering column bracket. Remove steering control unit. See the section Steering Housing and Steering Control Unit 1600 SRM 773 for information concerning repairs to the steering control unit.

WARNING

Steering Wheel and Column Assembly

WARNING The spring (8, Figure 2) used to operate the latch for locking the steering column has tension and can release with enough force to cause injury.

3. Install latch on steering column bracket using clevis pin and new cotter pin. Install washer and spring on rod in steering column bracket.

Then, using locking pliers on rod below spring and washer, raise rod and compress spring to seat rod in latch. Install latch knob using screws.

The spring (15, Figure 2) used between the steering column and the cowl mount has tension and can release with enough force to cause injury.

4. Remove plugs from hydraulic connections and install hydraulic steering hoses to steering control unit. Tighten hose fittings to 25 to 29 N•m (18 to 21 lbf ft).

10. Loosen four hex head bolts retaining shaft, spring, plate, and steering column to cowl.

Remove socket head bolt and nut that guides steering column through tilting positions from cowl bracket. Remove four hex head bolts, spring, and pin from cowl.

5. If the optional directional switch is used, install directional switch assembly to steering column bracket using two shoulder head bolts, spring washers, and nuts.

6. Identify and install electrical connections to directional switches.

INSTALL WARNING WARNING The spring (15, Figure 2) used between the steering column and the cowl mount has tension and can release with enough force to cause injury.

1. Align steering column with cowl mounting. See Figure 2. Install spring on shaft and plate. Align one end of spring in bracket on cowl and other end in steering column bracket. Install four hex head bolts and washers to retain steering column bracket, spring, and plate to cowl. Install socket head bolt through slot in steering column bracket. Apply Loctite No. 242 or equivalent on nut and install nut on inside of cowl. Tighten hex head bolts and nut to 25 N•m (18 lbf ft).

2. Install splined end of steering column in steering control unit. Install unit and column in steering control bracket. Install four hex head bolts and washers to retain unit and column to steering column bracket.

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

7. Install steering wheel on steering column shaft.

Install steering wheel hex nut and tighten nut to 40 to 54 N•m (30 to 40 lbf ft). Install electrical leads for horn to base plate and retain leads using hex head bolts. Install base plate, retaining ring, and horn cover in steering wheel.

WARNING The spring (23, Figure 2) used on the optical encoder has tension and can release with enough force to cause injury.

8. Install optical encoder on steering column using spring to retain unit.

9. Install key switch in bottom steering pod cover.

Install electrical connections to key switch.

5

Power Steering Pump and Motor 10. Align and install steering pod covers on steering column using six screws removed at disassembly.

Connect battery connector.

1600 SRM 769 11. Test steering of truck by slowly driving truck in an open area. Rotate steering wheel from lock to lock.

WARNING After making repairs, do not extend the hands or arms through the steering wheel. If the control unit was not assembled correctly or the hydraulic hose not connected correctly, it can rotate with a strong force and cause serious injury. If this action occurs, disassemble the control unit and correct the existing problem.

Power Steering Pump and Motor DESCRIPTION The power steering pump and motor are located under the floor plates on the left side of the truck. The power steering pump is a single-section gear pump which draws the hydraulic oil from the hydraulic tank and directs the oil to the steering control unit mounted in the steering column. The power steering motor and pump operate when the key switch is ON and the operator is on the seat (seat switch closed).

A timer stops the power steering motor 6 seconds after the operator is off the seat (seat switch open) and the key switch is still ON.

REMOVE The power steering pump and motor must be removed as a unit for servicing the pump. See Figure 4.

The power steering pump and motor are mounted to the frame with rubber isolator mounts. See Figure 5.

1. Disconnect battery. Remove battery to gain access to hex head bolts for mounting power steering pump and motor. Follow the instructions in Periodic Maintenance 8000 SRM 772 or the Operating Manual for battery removal information.

2. Remove floor plate on operator’s side of lift truck.

3. Mark electrical wires for identification at assembly. Remove electrical wires.

NOTE: If the unit being worked on has brush wear sensing or thermal sensing wires, be certain to remove these wires before attempting to remove the power steering pump and motor.

6

4. Disconnect suction line to power steering pump.

Remove in-line strainer from suction line. Disconnect discharge line from power steering pump. Plug both hydraulic lines and pump ports to prevent dirt from entering hydraulic system and to prevent hydraulic oil from leaking from system.

WARNING The power steering pump and motor are heavy. Be sure that all lifting devices (lifts, cables, chains, slings, etc.) are suitable and of adequate capacity to lift the power steering pump and motor. The power steering pump and motor can weigh approximately 13.6 kg (30 lb). The power steering motor has ceramic permanent magnets. If the motor falls, the magnets can be damaged.

5. Remove three capscrews, washers, and brackets retaining power steering pump and motor to lift truck frame.

6. Carefully lift power steering pump and motor out of lift truck.

7. If the motor must be serviced, follow the instructions found in the section DC Motor Maintenance 620 SRM 294.

1600 SRM 769

Power Steering Pump and Motor

Figure 4. Power Steering Arrangement

7

Power Steering Pump and Motor

1600 SRM 769 Legend for Figure 4

1. STEERING CONTROL UNIT 2. STEERING PUMP MOTOR 3. STEERING PUMP

4. ROTARY ACTUATOR 5. FEED LINE 6. RETURN LINE

7. BLEED POINT

2. Align power steering pump and motor and brackets with mount holes in frame. Install capscrews, washers, and nuts to retain pump and motor to lift truck frame. Tighten nuts to 25 N•m (18 lbf ft).

3. Remove plugs from discharge port and discharge line. Install discharge line into pump port.

Clean and inspect in-line strainer. Replace Install in-line in-line strainer if necessary. strainer in suction line. Install suction line on suction side of pump.

4. Install all electrical wires disconnected at time of removal.

5. Install floor plates.

6. Install battery. Follow the instructions in the Periodic Maintenance 8000 SRM 772 or the Operating Manual for battery installation information. Connect battery.

DISASSEMBLE 1. PLATE 2. BRACKET 3. ISOLATOR

4. MOTOR 5. PUMP 6. STRAINER

1. Mark pump and motor to ensure proper alignment at assembly. Remove two capscrews and washers retaining pump to motor. Separate pump from motor. See Figure 6.

Figure 5. Pump and Motor Mount

INSTALL WARNING The power steering pump and motor are heavy. Be sure that all lifting devices (lifts, cables, chains, slings, etc.) are suitable and of adequate capacity to lift the power steering pump and motor. The power steering pump and motor can weigh approximately 13.6 kg (30 lb). The power steering motor has ceramic permanent magnets. If the motor falls, the magnets can be damaged.

1. Carefully locate power steering pump and motor in lift truck.

8

2. Remove eight capscrews and washers retaining housing and cover together. Carefully separate cover from housing.

3. Remove gears, drive shaft, keys, spacer, and idler shaft and gear.

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

4. Remove snap rings and needle bearings.

1600 SRM 769

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6.

7.

HOUSING SCREW PLUG NEEDLE BEARING KEY SNAP RING GEAR

Power Steering Pump and Motor

8.

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SPACER COVER OIL SEAL DRIVE SHAFT GUIDE PIN GASKET IDLER SHAFT AND GEAR

Figure 6. Power Steering Pump 5. Clean and inspect needle bearings for damage.

Inspect gears, idler shaft and gear, and drive shaft for erosion or damage. Replace all defective parts. Replace oil seal and joints.

ASSEMBLE Lubricate all components with clean hydraulic oil before assembly.

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

1. Install needle bearings in pump halves. Install snap rings to retain bearings.

2. Install spacer on shafts. Install remaining two gears on shafts.

3. Install oil seal in upper half of pump. Carefully install drive shaft through oil seal and needle bearing. Install keys on drive shaft.

4. Install idler shaft and gear in needle bearing of upper half of pump. Align and install gear on drive shaft and key so it mates with idler gear.

5. Ensure housing and cover are properly aligned and install gasket. Install eight capscrews and washers retaining housing and cover together.

9

Steering Axle Components

1600 SRM 769

Steering Axle Components GENERAL The steering axle assembly has a horizontal shaft and gear assembly that extends through the gear housing, which is mounted in the rear of the truck frame. The shaft and gear assembly is rotated by the horizontal movement of a gear rack. The power steering pump feeds hydraulic oil to the steering control unit, which directs the oil to two pistons in the gear housing. These two pistons control the movement of the gear rack.

and installation of the wheel. Follow the instructions in Periodic Maintenance 8000 SRM 772 or the Operating Manual.

4. Using a suitable hoist or jacking equipment, raise rear of truck until wheels and tires are free to rotate. Put lift trucks on blocks; see How to Put Lift Truck on Blocks in either the Operating Manual or the Periodic Maintenance 8000 SRM 772.

WHEEL AND TIRE ASSEMBLY

5. Remove lug nuts and remove wheel assembly from steering axle.

Remove

Install

WARNING Before attempting to remove the wheel from the steering axle, put blocks under each side of the frame. The blocks must prevent the lift truck from falling and causing injury or damage. Do not place jacking equipment under the counterweight.

WARNING Deflate tire completely before removing the wheel from the lift truck. Air pressure in the tires can cause the tire and rim parts to explode, causing serious injury or death.

Never loosen the nuts that hold the inner and outer wheel halves together when there is air pressure in the tire.

NOTE: The instructions are for one wheel and tire assembly. If necessary, perform the same operation for the opposite side.

1. Turn steering wheel so wheel and tire assembly that is to be removed is accessible. Move key to OFF position. Disconnect battery.

WARNING Lifting and carrying of tires is not recommended because their weight could be in excess of 45 kg (100 lb). Where applicable, use a wheel or tire dolly to assist in the removal and installation of the wheel. Follow the instructions in Periodic Maintenance 8000 SRM 772 or the Operating Manual.

1. Align wheel and tire assembly with studs and install wheel and tire assembly on wheel hub.

2. Install lug nuts on studs to retain wheel assembly. Tighten nuts hand tight.

3. Lower lift truck to floor. Tighten lug nuts to 170 N•m (125 lbf ft).

4. Remove chocks from wheels. Connect battery.

5. After 2 to 5 hours of operation, check all wheel nuts. Tighten lug nuts in a cross pattern to 170 N•m (125 lbf ft). When nuts stay tight after an 8-hour check, the interval for checking the torque can be extended to 350 hours.

2. Chock drive wheels and apply parking brakes.

WHEEL HUB ASSEMBLY

3. Loosen lug nuts retaining wheel assembly.

Remove

WARNING Lifting and carrying of tires is not recommended because their weight could be in excess of 45 kg (100 lb). Where applicable, use a wheel or tire dolly to assist in the removal

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NOTE: The instructions are for one wheel hub assembly. If necessary, perform the same operation for the opposite side.

1. Remove wheel and tire assembly. See Wheel and Tire Assembly, Remove.

1600 SRM 769 2. Remove hub cap. Straighten, remove, and discard cotter pin. Remove nut, washer, spacer, and hub assembly.

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

3. Remove and discard nilos sealing rings from hub.

Use a soft, metal drift to remove bearings. Remove bearing cones.

4. Inspect bearings for damage. Inspect axle shaft for damage or corrosion. Inspect wheel studs for damage. Replace all damaged components.

Install 1. Prior to installation, pack bearings and new nilos sealing rings with grease. See the section Periodic Maintenance 8000 SRM 772 or the Operating Manual for the recommended grease.

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

2. Install snap rings in hub to retain bearings.

Make certain snap rings are seated in wheel hub. Install both inner and outer wheel bearings in hub. Install inner nilos sealing ring.

3. Carefully install hub on axle so seal is not damaged. Install outer nilos sealing ring.

4. Install spacer and washer on axle. Install slotted nut. Tighten nut to 47 N•m (35 lbf ft). Rotate wheel while tightening nut. If necessary, back off on the nut to align nut and hole in axle shaft.

Steering Axle Components

STEERING AXLE ASSEMBLY Remove NOTE: The removal instructions listed are done with the counterweight, wheels, and tires installed.

1. Disconnect battery connector. Block drive tires.

Position blocks between steer tires and steering axle weldment to prevent tires and wheels from rotating. Remove wheel assembly.

2. Remove two capscrews that retain rear cover to counterweight. Remove rear cover.

WARNING The capacitors in the traction controllers can hold an electrical charge after the battery is disconnected. To prevent electrical shock and injury, discharge the capacitors after disconnecting the battery connector and before repairing or replacing any component in the rear compartment. Wear safety glasses. Make certain the battery has been disconnected. Discharge the capacitors in the controllers by connecting a 200-ohm, 2-watt resistor across the controller’s POS and NEG terminals (outer two power cable terminals). 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.

See Figure 7.

3. Discharge controller capacitors.

4. Unscrew cylinder from gear housing. Remove O-ring from gear housing. See Figure 8.

5. Remove piston from inside cylinder.

NOTE: Two screwdrivers with well-rounded and slightly bent tips (approximately 10 degrees) will aid in the removal and installation of the seals.

6. Remove two piston guideways and compact seal from piston.

5. Install new cotter pin. Install hub cap.

7. Remove four capscrews that fasten yoke assembly and gear housing shaft assembly. Separate shaft assembly from yoke assembly.

6. Install wheel assembly. See Wheel and Tire Assembly, Install.

8. Remove protection cover from end of yoke shaft.

Remove cotter pin, nut, and U-disc.

7. Remove chocks from drive wheels. Connect battery.

9. Remove assembled wheel hub from yoke shaft.

Remove bearings and wheel bolts if necessary.

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Steering Axle Components 10. Remove nilos ring from yoke shaft.

11. Remove nut, washer, shims, nilos ring, and bearings from flange shaft.

1600 SRM 769 3. Make sure all surfaces are free of scratches and sharp edges.

Install WARNING After making repairs, do not extend the hands or arms through the center of the steering wheel. If the control unit was not assembled correctly or the hoses not connected correctly, it can rotate with a strong force and cause serious injury. If this action occurs, disassemble the control unit and correct the existing problem.

NOTE: Use new seals and O-rings during assembly.

Lubricate all parts with clean hydraulic oil.

1. Install shaft seal and bearing raceway into bottom of gear housing. See Figure 8.

2. Install safety ring in groove at top of gear housing. Install shaft seal into top of gear housing.

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POSITIVE POWER CABLE CONNECTION NEGATIVE POWER CABLE CONNECTION INSULATED JUMPER WIRES 200-OHM, 2-WATT RESISTOR Figure 7. Discharging Capacitors

12. Remove flange shaft from gear housing.

13. Remove bearing and nilos ring from flange shaft.

14. Slide gear rack out of gear housing. Remove liners from each end of gear housing.

15. Remove safety ring, shaft seals, and bearing raceway from top and bottom opening of gear housing if necessary.

Clean WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s recommended safety precautions and procedures.

1. Clean all parts in solvent.

2. Dry parts with compressed air. Do not dry parts with a cloth.

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3. Install liners into each end of gear housing. Install gear rack through both liners in gear housing, making sure middle groove of gear rack is located in middle of gear housing.

4. Fill nilos ring with grease and position ring over flange shaft. Press bearing on flange shaft.

5. Install flange shaft through gear housing. Install selected shims, bearing, nilos ring, additional shims, washer, and nut over end of flange shaft.

6. Install five wheel bolts into each wheel hub.

Press bearings into each end of wheel hubs. Fill nilos ring with grease and place it over yoke shaft. Install assembled wheel hub over yoke shaft. Fill inside area of wheel hub with grease.

7. Install U-disc and nut over end of yoke shaft.

Tighten nut firmly and secure assembly in place with cotter pin. Install protection cover over end of yoke shaft.

8. Assemble yoke assembly to gear housing with shaft assembly. A pressed pin in yoke will help to properly align the two assemblies. Fasten the two assemblies together with four capscrews.

9. Install two piston guideways and a compact seal over piston. Install piston into cylinder and push piston to end of cylinder.

1600 SRM 769

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4.

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8.

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NUT WASHER SHIM NILOS RING BEARING SHIM SAFETY RING SHAFT SEAL PISTON GUIDEWAY COMPACT SEAL CYLINDER

Steering Axle Components

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PISTON O-RING LINER GEAR RACK HOUSING SHAFT SEAL RACEWAY PROTECTION COVER NUT COTTER PIN U-DISC

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BEARING WHEEL HUB BEARING NILOS RING WHEEL BOLT CAPSCREW FLANGE SHAFT NILOS RING BEARING PLUG SCREW

Figure 8. Steering Axle Assembly

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Operation Check

1600 SRM 769

10. Fill cylinder with 125 cm 3 of grease.

11. Apply a light film of hydraulic oil on cylinder and O-ring. Install O-ring into gear housing on top of liners. Screw cylinder into end of gear housing.

12. Operate unit several times. Install plug screw into gear housing.

13. Connect battery connector. Remove blocks from between tires and steer axle.

14. Install rear compartment cover. Lower lift truck to floor and remove blocks from drive wheels.

Test operate lift truck before returning lift truck to service.

Steering System Air Removal If there is air in the hydraulic lines of the steering system, the operation will not be smooth. The steering system must be purged of all air at assembly in order to operate properly. This is normally done by simply turning the steering wheel from lock to lock about six times. No further bleeding should be required. If that doesn’t remove the air, then follow the steps below: 1. Bleed air from one steering cylinder at a time.

2. Disconnect hydraulic hose from one of the steering cylinders and attach a tee fitting to steering cylinder. Connect hydraulic hose and a short extension hose to tee. Be careful to catch all oil in

a drip pan. Place free end of extension hose into drip pan.

3. Slowly turn steering wheel fully counterclockwise to lock, or until oil comes from hose.

4. Slowly turn steering wheel continuously clockwise to lock, or until oil comes from hose.

5. Disconnect tee fitting and reconnect hydraulic hose fittings at steering cylinders and repeat Step 1 through Step 5 on the other side.

Operation Check The purpose of this check is to make sure the steering trunnion turns the correct degrees of its rotation (approximately 180 degrees). Put lift truck on blocks so weight of lift truck is removed from steering trunnion.

Operate power steering system. Rotate trunnion to its stop in one direction, then rotate trunnion to its stop in the other direction. Check that steering wheel turns trunnion smoothly. The face of the

14

wheel should be approximately parallel to the frame plate at the back of the battery compartment when the steering trunnion is rotated fully in each direction to its stops.

To check the operation of the printed circuit card that controls the steering, see the section SX/SR Transistor Motor Controllers and Handset 2200 SRM 774.

1600 SRM 769

Troubleshooting

Steering Pressure Check NOTE: The correct relief valve pressure is 7.7 ±0.34 MPa (1100 ±50 psi).

1. Install a pressure gauge in power steering pump discharge line (between pump and steering control unit). See Figure 9.

2. Operate steering pump and rotate steering wheel so relief valve (in steering control unit) operates.

Check that maximum pressure is 7.7 ±0.34 MPa (1100 ±50 psi).

3. If pressure is greater than 8.05 MPa (1150 psi), or less than 7.35 MPa (1050 psi), replace steering control unit.

4. When pressure checks are complete, remove pressure gauge.

5. Operate power steering system. Rotate trunnion to its stop in one direction, then rotate trunnion to its stop in the other direction. Check that steering turns trunnion smoothly. The face of the wheel should be approximately parallel to the frame plate at the back of the battery compartment when steering trunnion is rotated fully in each direction to its stops.

To check the operation of the printed circuit card that controls the steering, see the section SX/SR Transistor Motor Controllers and Handset 2200 SRM 774.

1.

2.

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4.

LH RH R-PORT STEERING CONTROL UNIT 5. RELIEF 75 bar (1100 psi)

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9.

HYDRAULIC TANK STEERING PUMP STRAINER L-PORT

Figure 9. Hydraulic Schematic

Troubleshooting PROBLEM

POSSIBLE CAUSE

PROCEDURE OR ACTION

15

Troubleshooting

PROBLEM There is no action when the steering wheel is turned.

The axle does not turn when the steering wheel is turned.

The axle rotates in the wrong direction from the direction of the steering wheel.

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1600 SRM 769

POSSIBLE CAUSE

PROCEDURE OR ACTION

The steering pump fuse is open.

Check the steering pump fuse and replace if open.

The hydraulic oil level is low or there is no oil in the tank.

Fill the hydraulic oil to the correct level.

No oil flow from the steering control unit to the rotary actuator.

Remove, clean, and install the steering control unit, hoses, and rotary actuator.

The sleeve and spool in the steering control unit will not move.

Clean or replace steering control unit.

Hydraulic hoses or connections are open.

Tighten hose connections; if leaks continue, replace hoses.

The steering control unit needs repair.

Repair or replace steering control unit.

See the section Steering Housing and Steering Control Unit 1600 SRM 773.

The electric motor for the steering pump needs repair.

Repair or replace steering motor.

Air in the steering hydraulic system.

Exercise the system until all air is removed by the system.

Steering pump does not send oil to the steering system.

Inspect the fuse; replace if open.

The hydraulic lines are connected incorrectly at the rotary actuator.

Reconnect hydraulic hoses correctly.

The hydraulic lines are connected incorrectly at the steering control unit.

Reconnect hydraulic hoses correctly.

If the steering control unit was disassembled, check the rotor for correct alignment.

Disassemble steering control unit and align rotor correctly.

1600 SRM 769

PROBLEM The axle continues to turn after the steering wheel has stopped turning.

The power steering pump makes noise that is not normal.

Slow or difficult steering.

Troubleshooting

POSSIBLE CAUSE

PROCEDURE OR ACTION

A centering spring is broken in the steering control unit.

Repair or replace steering control unit.

There is damage to the sleeve or the spool of the steering control unit.

Repair or replace steering control unit.

Check for dirt in the hydraulic system and the steering control unit.

Drain hydraulic oil completely and replace with new hydraulic oil and a new hydraulic oil filter.

There is air entering the power steering pump.

Check for air entering the pump through the inlet port or the seals between the pump and the motor.

The bearings in the electric motor or the power steering pump need repair.

Replace bearings in steering pump motor.

Dirty inlet strainer.

Clean inlet strainer oil-based solvent.

The hydraulic oil level is low or there is no oil in the tank.

Refill hydraulic oil in tank.

No oil flow from the steering control unit to the rotary actuator.

Remove, clean, and install the steering control unit, hoses, and rotary actuator.

Steering gearbox seals leaking.

Replace seals.

The sleeve and spool in the steering control unit are binding.

Clean or replace steering control unit.

Low hydraulic oil pressure.

Check pump for correct operation.

The steering control unit needs repair.

See the section Steering Housing and Steering Control Unit 1600 SRM 773.

On-demand module defective.

Replace module.

using

an

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Troubleshooting

PROBLEM

1600 SRM 769

POSSIBLE CAUSE

PROCEDURE OR ACTION

The power steer pump pressure is too high or too low.

The power steer hydraulic oil relief pressure at the steering control unit inlet should be 7.7 MPa (1100 psi).

If necessary, adjust the relief pressure by removing the protective cap and adjusting the relief valve. Install the protective cap and check the pressure again. If the proper setting cannot be obtained, remove the relief valve. Clean and inspect the relief valve for contamination. Assemble the relief valve and check the pressure again. If the proper relief valve pressure still cannot be obtained, replace the steering control unit.

The power steer pump and motor is overheating (for 36-volt lift trucks).

Incorrect hydraulic pressure and current draw at idle, medium steering, and relief.

Check the power steer pump and motor hydraulic pressures and current draws at idle, medium steering, and relief. The pressure and current draws should be as follows: Idle (pump running, no steering) - 0.42 to 0.56 MPa (60 to 80 psi) - 4 to 6 amps.

Medium Steering and Relief 5.60 to 5.95 MPa (800 to 850 psi) - 20 to 25 amps.

Relief (turn wheel clockwise or counterclockwise to stop) 7.7 MPa (1100 psi) - 30 to 35 amps. a. If the momentary motor current draw at relief is 45 amps or above, replace the pump. b. If the motor current draw at idle is 10 amps or more and the relief pressure is normal, check the entire hydraulic system for contamination. Replace or clean all filters and strainers, back flush the system (especially the steering control unit), and fill the hydraulic system with clean hydraulic oil. If high idle current draw still persists, check for kinked hoses before replacing the steering control unit or finally the power steer pump and motor assembly.

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1600 SRM 769

PROBLEM The power steer pump and motor is overheating (for 48-volt lift trucks).

Troubleshooting

POSSIBLE CAUSE Incorrect hydraulic pressure and current draw at idle, medium steering, and relief.

PROCEDURE OR ACTION Check the power steer pump and motor hydraulic pressures and current draws at idle, medium steering, and relief. The pressure and current draws should be as follows: Idle (pump running, no steering) - 0.28 to 0.42 MPa (40 to 60 psi) - 4 to 6 amps.

Medium Steering and Relief 5.60 to 5.95 MPa (800 to 850 psi) - 20 to 25 amps.

Relief (turn wheel clockwise or counterclockwise to stop) 7.7 MPa (1100 psi) - 30 to 35 amps. a. If the momentary motor current draw at relief is 45 amps or above, replace the pump. b. If the motor current draw at idle is 10 amps or more and the relief pressure is normal, check the entire hydraulic system for contamination. Replace or clean all filters and strainers, back flush the system (especially the steering control unit), and fill the hydraulic system with clean hydraulic oil. If high idle current draw still persists, check for kinked hoses before replacing the steering control unit or finally the power steer pump and motor assembly.

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NOTES ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

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TECHNICAL PUBLICATIONS 1600 SRM 769

3/02 (8/99) Printed in U.S.A.

PERIODIC MAINTENANCE J30-40XMT2 [H160]

PART NO. 1468300

8000 SRM 772

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR • When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks.

• Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit 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!

Periodic Maintenance

Table of Contents

TABLE OF CONTENTS General ...............................................................................................................................................................

How to Move Disabled Lift Truck .................................................................................................................

How to Tow Lift Truck...............................................................................................................................

How to Put Lift Truck on Blocks...................................................................................................................

How to Raise Drive Tires ..........................................................................................................................

How to Raise Steer Tires...........................................................................................................................

Maintenance Schedule.......................................................................................................................................

Maintenance Procedures Every 8 Hours or Daily............................................................................................

Before Operation Checks...............................................................................................................................

Hydraulic System ......................................................................................................................................

Battery .......................................................................................................................................................

Battery Restraint System .........................................................................................................................

Tires and Wheels .......................................................................................................................................

Safety Procedures When Working Near Mast .............................................................................................

Forks ..........................................................................................................................................................

Adjust.....................................................................................................................................................

Remove ..................................................................................................................................................

Inspect ...................................................................................................................................................

Install.....................................................................................................................................................

Mast and Lift Chains ................................................................................................................................

Lift Chain, Adjustment .............................................................................................................................

Operation Check ............................................................................................................................................

Gauges and Horn.......................................................................................................................................

Control Levers and Pedals........................................................................................................................

Service Brakes ...........................................................................................................................................

Parking Brake ...........................................................................................................................................

Steering System ........................................................................................................................................

Maintenance Procedures Every 350 Hours or 3 Months .................................................................................

Hydraulic Tank Breather ..............................................................................................................................

Wheel Nut Torque..........................................................................................................................................

Steering Actuator Mounting Bolts................................................................................................................

Transaxle........................................................................................................................................................

Lift System Operation ...................................................................................................................................

Mast................................................................................................................................................................

Lift Chains .....................................................................................................................................................

Forks...............................................................................................................................................................

Safety Labels..................................................................................................................................................

Brake Fluid ....................................................................................................................................................

Other Lubrication ..........................................................................................................................................

Electrical Inspection......................................................................................................................................

Special Precautions ...................................................................................................................................

Contactors..................................................................................................................................................

Motor Brushes ...........................................................................................................................................

Parking Brake ...........................................................................................................................................

Maintenance Procedures Every 2000 Hours or Yearly ....................................................................................

Hydraulic System ..........................................................................................................................................

Hydraulic Oil Filter, Change ....................................................................................................................

Hydraulic Oil Strainer, Check ..................................................................................................................

Hydraulic Oil, Change ..............................................................................................................................

Brakes ............................................................................................................................................................

Parking Brake, Adjust ..............................................................................................................................

©2003 HYSTER COMPANY

1 1 1 2 2 3 4 8 8 8 9 9 10 11 13 13 14 14 14 15 16 17 17 17 17 17 17 18 18 18 18 18 19 19 21 22 22 22 22 22 22 23 23 24 30 30 30 30 30 31 31

i

Table of Contents

Periodic Maintenance

TABLE OF CONTENTS (Continued) Transaxle........................................................................................................................................................

Maintenance Procedures Every 4000 Hours ....................................................................................................

Transaxle........................................................................................................................................................

Lift and Tilt System Leak Check ......................................................................................................................

Lift System.....................................................................................................................................................

Tilt System .....................................................................................................................................................

Battery Maintenance .........................................................................................................................................

How to Charge Battery..................................................................................................................................

How to Change Battery .................................................................................................................................

Battery Size Specifications............................................................................................................................

Wheels and Tires Maintenance .........................................................................................................................

General ...........................................................................................................................................................

How to Change Tires .....................................................................................................................................

Steer and Drive Wheels.................................................................................................................................

Pneumatic Tires.............................................................................................................................................

Remove Wheel From Lift Truck ...............................................................................................................

Tire Sizes and Pressures...........................................................................................................................

Remove Tire From Wheel .........................................................................................................................

Install Tire on Wheel.................................................................................................................................

Add Air to Tires .........................................................................................................................................

Pneumatic-Shaped Solid Tires......................................................................................................................

Remove Wheel From Lift Truck ...............................................................................................................

Press Tire From Wheel .............................................................................................................................

Install Tire on Wheel.................................................................................................................................

Install Wheel and Tire...................................................................................................................................

This section is for the following models: J30-40XMT2 [H160]

ii

31 33 33 33 33 34 34 34 35 36 38 38 38 38 38 38 39 40 41 42 42 42 43 44 46

8000 SRM 772

General

General When turning the key switch to the ON position, the Brush Wear Indicator and Motor Temperature Indicator will illuminate. Contact your dealer if the Brush Wear Indicator and Motor Temperature Indicator will not illuminate when turning the key switch to the ON position.

This manual contains a Maintenance Schedule and the instructions for maintenance and inspection. The Maintenance Schedule has time intervals for inspection, lubrication, and maintenance. The time intervals are based on a normal operation. A 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 both authorization and training. Repairs and adjustments that are not correct can make 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.

Your Hyster lift truck dealer has the facilities and trained personnel to do the maintenance. A complete program of inspection, lubrication, and maintenance will help your lift truck perform efficiently and operate over a longer period of time.

Some users have service personnel and facilities to do the items listed in the Maintenance Schedule.

Workshop manuals are available from your Hyster lift truck dealer to help users who do their own maintenance.

Do not make repairs or adjustments unless specifically authorized to do so.

Put the lift truck on a level surface. Lower the carriage and forks, apply the parking brake, and turn the key switch to OFF. Open the access panels and inspect for leaks and conditions that are not normal.

Clean any oil spills. Make sure that lint, dust, paper,

and other materials are removed from the compartments.

HOW TO MOVE DISABLED LIFT TRUCK How to Tow Lift Truck WARNING Use extra care when moving a lift truck during the following conditions: • Brakes do not operate correctly.

• Steering does not operate correctly.

• Tires are damaged.

• Traction conditions are bad.

• The lift truck must be moved on a steep grade.

If the steering pump motor does not operate, steering control of the lift truck can be slow.

This can make the control of the lift truck difficult. If there is no electrical power, steering can be difficult. Do not tow the lift truck if there is no power. Poor traction can cause the disabled lift truck or towing vehicle to slide.

Steep grades will require additional brake force to stop the lift truck.

Never carry a disabled lift truck unless the lift truck MUST be moved and cannot be towed.

The lift truck used to carry the disabled lift truck MUST have a rated capacity equal to or greater than the weight of the disabled lift truck. The capacity must be for a load center equal to half the width of the disabled lift truck. See the Nameplate of the disabled lift truck for the approximate total weight.

The forks must extend the full width of the disabled lift truck. Center the weight of the disabled lift truck on the forks and be careful not to damage the under side of the lift truck.

1. The towed lift truck must have an operator.

2. Tow the lift truck slowly.

3. Raise the carriage and forks approximately 30 cm (12 in.) from the surface. Install a chain to prevent the carriage and mast channels from moving.

1

General

8000 SRM 772

4. If another lift truck is used to tow the disabled lift truck, that lift truck must have an equal or larger capacity than the disabled lift truck. Install an approximate half-capacity load on the forks of the lift truck that is being used to tow the disabled lift truck. This half-capacity load will increase the traction of the lift truck. Keep the load as low as possible.

a. Before removing the mast and load wheels, put blocks under the rear of the frame so that the lift truck cannot fall backward or to the side. b. Before removing the battery and/or the counterweight, put blocks under the mast assembly so that the lift truck cannot fall forward.

5. Use a towing link made of steel that attaches to the tow pins in the counterweights of both lift trucks.

Put the lift truck on blocks only if the surface is solid, even, and level. Make sure that any blocks used to support the lift truck are solid, one-piece units. Put blocks in front and back of the tires to prevent movement of the lift truck.

HOW TO PUT LIFT TRUCK ON BLOCKS

NOTE: Some lift trucks have lifting eyes. These lift points can be used to raise the lift truck so that blocks can be installed.

How to Raise Drive Tires WARNING The lift truck must be put on blocks for some types of maintenance and repair. The removal of the following assemblies will cause large changes in the center of gravity: mast and load axle, battery, and counterweight. When the lift truck is put on blocks, put additional blocks in the following positions:

1. Put blocks on each side (front and back) of the steer tires to prevent movement of the lift truck.

See Figure 1.

1. DRIVE TIRES

2. STEER TIRES Figure 1. Putting Lift Truck on Blocks

2

8000 SRM 772 2. Use a hydraulic jack under the side of the frame near the front. Make sure that the jack has a capacity equal to at least half the weight of the lift truck. See the Nameplate for weight specifications.

3. Put a block under each outer mast channel.

4. Put additional blocks under the frame behind the drive tires.

How to Raise Steer Tires WARNING The lift truck must be put on blocks for some types of maintenance and repair. The removal of the following assemblies will cause large changes in the center of gravity: mast and load axle, battery, and counterweight. When the lift truck is put on blocks, put additional blocks in the following positions: a. Before removing the mast and load wheels, put blocks under the rear of the frame so that the lift truck cannot fall backward or to the side. b. Before removing the battery and/or the counterweight, put blocks under the mast

General assembly so that the lift truck cannot fall forward.

Put the lift truck on blocks only if the surface is solid, even, and level. Make sure that any blocks used to support the lift truck are solid, one-piece units. Put blocks in front and back of the tires to prevent movement of the lift truck.

NOTE: Some lift trucks have lifting eyes. These lift points can be used to raise the lift truck so that blocks can be installed.

1. Apply the parking brake. Put blocks on both sides (front and back) of the drive tires to prevent movement of the lift truck. See Figure 1.

2. Use hydraulic jacks to raise the steer tire. Make sure that the jacks have a capacity of at least 2/3 of the total weight of the lift truck as shown on the Nameplate.

3. Put the jacks under the rear of the frame to raise the lift truck. Put blocks under the frame to support the lift truck.

3

Maintenance Schedule

8000 SRM 772

Maintenance Schedule NOTE: Item Nos. in Table 1 refer to Figure 2.

The Maintenance Schedule has two time periods in which the service engineer can perform the maintenance. For lift trucks operated less than 8 hours each day, use Maintenance Procedures Every 8 Hours or Daily, Maintenance Procedures Every 350 Hours or 3 Months, and Maintenance Procedures Every 2000

Hours or Yearly schedules. For lift trucks operated more than 8 hours each day, use Maintenance Procedures Every 8 Hours or Daily, Maintenance Procedures Every 350 Hours or 3 Months, and Maintenance Procedures Every 2000 Hours or Yearly schedules. See Figure 2 and Table 1.

Figure 2. Maintenance Points

4

8000 SRM 772

Maintenance Schedule Table 1. Maintenance Schedule

Item No.

Item

8 hr or 1 day 4

350 hr or month 4 5

1

Battery

X

2

Brake, Parking

X

Push Pins, Lever

Caliper Lever Washer

L

Linkage

L

X

Check Condition

Cable

X

C

Check Condition

X

Check Condition

Brake, Service

X

1.1 liter (37 oz) X

4

Directional/Speed Control

X

5

Electrical Circuits

X

Check Operation

Multipurpose Grease 6

L

Check Operation

Silicon Spray Lubricant 3

Check Operation Check Condition

Motor Brushes

X

Check Condition

X X

Gauges, Horn, Lights, Fuses

X

SAE J-1703 Brake Fluid

L

X

Fork Guides and Locks

Multipurpose Grease 6

Check Condition

Contactors

Forks

See Battery Maintenance

Check Operation X

Linkage

Specification

Antiseize Compound 7

L

Brake Pads

7

Check Level

Caliper

Brake Fluid

6

Procedure or Quantity

Check Operation

Pads 3

2000 hr or 1 year 4

Check for Damage L

As Required

Silicone Spray Lubricant 3

Check Operation

X = Check C = Change L = Lubricate 1

Hydraulic Oil - HCE-4

2

Chevron EP - HCE-79

3

Silicone Spray - Hyster P/N 328388 or equivalent

4

Whichever comes first

5

Equalization Charge approximately each month but not more than each week

6

Multipurpose Grease with 2-4% Molybdenum Disulfide for normal operations - Hyster P/N 328388 or equivalent 7

Antiseize - Hyster P/N 251979 or equivalent

NOTE: Never use steam to clean electrical parts.

5

Maintenance Schedule

8000 SRM 772

Table 1. Maintenance Schedule (Continued) Item No. 8

Item

8 hr or 1 day 4

Hydraulic Oil Leaks

X

Hydraulic Oil Level (Full Mark)

X

Dipstick/Breather Cap

350 hr or month 4

2000 hr or 1 year 4

Procedure or Quantity

Specification

Check for Leaks C X

18 liter (4.75 gal) Above 0 C (32 F) 1 Below 0 C2 Clean or Replace

See Parts Manual

Hydraulic Oil Filter

C

Replace

See Parts Manual

Hydraulic Oil Strainer

C

Clean or Replace

See Parts Manual

9

Lift Chains

X

10

Mast

X

L

Check for Damage Engine Oil Check Operation

Pivots, Sliding Surfaces

L

As Required

Multipurpose Grease 6

Trunnion Hex. Head Bolt

X

Tighten if Required

90 N•m (66 lbf ft)

Trunnion Bush

L

2 Lube Fittings

Multipurpose Grease 6

L

As Required

Silicone Spray Lubricant 3 See Parts Manual

11

Pedals, Levers, Seat Rails, Cables, Hinges, Linkages

12

Safety Labels and Operating Manual

X

Replace if Necessary

13

Steering Operation

X

Check Operation

X = Check C = Change L = Lubricate 1

Hydraulic Oil - HCE-4

2

Chevron EP - HCE-79

3

Silicone Spray - Hyster P/N 328388 or equivalent

4

Whichever comes first

5

Equalization Charge approximately each month but not more than each week

6

Multipurpose Grease with 2-4% Molybdenum Disulfide for normal operations - Hyster P/N 328388 or equivalent 7

Antiseize - Hyster P/N 251979 or equivalent

NOTE: Never use steam to clean electrical parts.

6

8000 SRM 772

Maintenance Schedule

Table 1. Maintenance Schedule (Continued) Item No. 14

15

Item

8 hr or 1 day 4

Steering Wheel Nuts

350 hr or month 4

2000 hr or 1 year 4

X

Procedure or Quantity

Specification

Tighten if Required

170 N•m (125 lbf ft)

Steering Actuator Hex Head Bolts

X

Tighten if Required

86 N•m (63 lbf ft)

Steering Axle Interrupter Bolt

X

Tighten if Required

84 N•m (62 lbf ft)

X

Check Condition

See Nameplate

X

Check Pressure

Tire and Wheels - Drive and Steering Tire Pressure Pneumatic

16

Transaxle Oil Level

X

17

Drive Wheel Bolt Torque

X

18

Transaxle Outer Pinion Bearings

C

Lubricate Every 4000 hr

See Procedure for SAE 80W-90 or Gear Oil Capacity Mobilgear 627 Tighten if Required

170 N•m (125 lbf ft)

1 Lube Fitting Each Transaxle

Multipurpose Grease 6

X = Check C = Change L = Lubricate 1

Hydraulic Oil - HCE-4

2

Chevron EP - HCE-79

3

Silicone Spray - Hyster P/N 328388 or equivalent

4

Whichever comes first

5

Equalization Charge approximately each month but not more than each week

6

Multipurpose Grease with 2-4% Molybdenum Disulfide for normal operations - Hyster P/N 328388 or equivalent 7

Antiseize - Hyster P/N 251979 or equivalent

NOTE: Never use steam to clean electrical parts.

7

Maintenance Procedures Every 8 Hours or Daily

8000 SRM 772

Maintenance Procedures Every 8 Hours or Daily WARNING Do not operate a lift truck that needs repairs.

If a repair is necessary, put a DO NOT OPERATE tag in the operator’s area. Remove the key from the key switch.

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, put a tag in the operator’s area that indicates the lift truck cannot be operated. DO NOT operate a lift truck until the problems are corrected.

BEFORE OPERATION CHECKS Make the following checks: • Oil level in the hydraulic tank • Electrolyte and specific gravity of the battery • Make sure the battery is clean and the correct size and weight for the lift truck • Operation of the battery restraint and latch mechanism

1.

2.

3.

4.

CONTROL VALVE DIPSTICK AND FILL TUBE LIFT PUMP AND MOTOR POWER STEERING PUMP AND MOTOR

• Condition of the wheels and tires • Condition of the forks, carriage, mast, and overhead guard • Leaks in the hydraulic system

Hydraulic System WARNING At operating temperature, the hydraulic oil is HOT. Do not permit the oil to contact the skin and cause a burn.

CAUTION Do not permit dirt to enter the hydraulic system when the oil level is checked or the filter is changed.

Never operate the pump without oil in the hydraulic system. The operation of the hydraulic pump without oil will damage the pump.

See Figure 3.

5.

6.

7.

8.

STRAINER HYDRAULIC TANK DRAIN PLUG FILTER

Figure 3. Hydraulic Tank and Pump Arrangement

8

8000 SRM 772

Battery WARNING Make sure the key switch is OFF and the park brake is set before connecting the battery.

If the lift truck was operated with a discharged battery, check all contactors for welded tips before a charged battery is connected.

WARNING Do not put tools on 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 immediately.

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 will operate correctly.

Use spacers to prevent the battery from moving more than 13 mm (0.5 in.) in any direction.

Check the hydraulic oil level when the oil is at operating temperature, the carriage is lowered, and the key switch is OFF. Add hydraulic oil only as needed.

If more hydraulic oil is added than the FULL level, hydraulic oil will leak from the breather during operation.

Maintenance Procedures Every 8 Hours or Daily in the area to repair any damage. Check the level of the electrolyte daily on a minimum 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.

Battery Restraint System WARNING The battery restraint and its latch mechanism must operate correctly before the lift truck is operated. See Figure 4.

The hood assembly is also a battery restraint. The function of the battery restraint, when the hood is correctly locked to the frame, is to hold the battery in the battery compartment if the lift truck tips over.

A sliding latch mechanism on the front of the hood locks the hood to the frame. The sliding latch unlocks the hood from the frame so the hood can be raised to the open position for access to the battery. The hood is also the support for the seat. A spring brace holds the seat and hood assembly in the open position.

Make sure the latch mechanism operates correctly.

Check that the latch is not worn and fully engages the frame. The hood must be locked in the closed position when the lift truck is operated. Try to raise the seat and hood when the hood is locked in the closed position. If the latch mechanism does not lock the hood in the closed position, do not operate the lift truck.

Make sure the battery weight is within the maximum 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 (baking 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 as shown on the Nameplate.

Inspect the battery case, connector, and cables for damage, cracks, or breaks. See the battery dealer

1. SLIDING LATCH MECHANISM

2. HOOD 3. FRAME

Figure 4. Battery Restraint Latch Mechanism

9

Maintenance Procedures Every 8 Hours or Daily

Tires and Wheels WARNING Air pressure in tires can cause tire and wheel parts to explode. This action can cause serious injury or death.

Completely deflate the tire before loosening the wheel nuts.

If the air pressure is less than 80 percent of the correct pressure, the tire must be removed.

Put the tire in a safety cage when adding air pressure to the tire. Follow the procedures under Wheels and Tires Maintenance.

When adding air to the tires, use a remote air nozzle. The person adding air pressure to the tire must stand to the side and not in front of the tire.

8000 SRM 772

WARNING When working on or near the mast or carriage, see Safety Procedures When Working Near Mast.

CAUTION When the wheels have been installed, check all wheel nuts after 2 to 5 hours of operation.

Tighten the nuts in a cross pattern to the correct torque value shown in the Maintenance Schedule. When the nuts stay tight after an 8-hour check, the interval for checking the torque can be extended to 350 hours.

Make sure the wheel nuts are tight. Tighten the wheel nuts in a cross pattern to the correct torque value shown in the Maintenance Schedule.

Keep the tires at the correct air pressure. See the Nameplate. Check the air pressure with a gauge when the tires are cold. See Figure 5. If it is necessary to add air to a tire that is warm, check one of the other tires and add air to the tire that has low pressure so the air pressures are equal. The air pressure of warm tires must always be equal to or greater than air pressures specified for cold tires.

Inspect the tires for wire, rocks, glass, pieces of metal, holes, cuts, and other damage. Remove any object that will cause damage. Check pneumatic wheels for bent or damaged rims. Check for loose or missing hardware. Remove any wire, strapping, or other material that is wrapped around the axle.

10

1. CHECK TIRE PRESSURE

2. CHECK FOR DAMAGE

Figure 5. Tires Check

8000 SRM 772

SAFETY PROCEDURES WHEN WORKING NEAR MAST The following procedures must be used when inspecting or working near the mast. Additional precautions and procedures can be required when repairing or removing the mast.

WARNING Mast parts are heavy and can move. Distances between parts are small. Serious injury or death can result if part of the body is hit by parts of the mast or the carriage.

• Never put any part of the body into or under the mast or carriage unless all parts are completely lowered or a safety chain is installed.

Also make sure that the power is off and the key is removed. Put a DO NOT OPERATE tag in the operator’s compartment. Disconnect the battery on electric lift trucks and put a tag or lock on the battery connector.

• Be careful of the forks. When the mast is raised, the forks can be at a height that could cause an injury.

• Do NOT climb on the mast or lift truck at any time. Use a ladder or personnel lift to work on the mast.

• Do NOT use blocks to support the mast weldments nor to restrain their movement.

• Mast repairs require disassembly and removal of parts and can require removal of the mast or carriage. Follow the repair procedures in the correct Service Manual section for the mast.

WHEN WORKING NEAR THE MAST, ALWAYS: 1. Lower the mast and carriage completely. Push the lift/lower control lever forward and make sure there is no movement in the mast. Make sure all parts of the mast that move are fully lowered.

OR

Maintenance Procedures Every 8 Hours or Daily 2. If parts of the mast must be in raised position, install a safety chain to restrain the moving parts of the mast. Connect moving parts to a part that does not move. Follow these procedures: a. Put the mast in a vertical position. b. Raise the mast to align the bottom crossmember of the weldment that moves in the outer weldment with a crossmember on the outer weldment. On the two-stage and freelift masts, the moving part is the inner weldment. On the three-stage mast, it is the intermediate weldment. On the four-stage mast, it is the first intermediate weldment.

See Figure 6. c. Use a 3/8-inch minimum safety chain with a hook to fasten the crossmembers together so the movable member cannot lower. Put the hook on the back side of the mast. Make sure the hook is completely engaged with a link in the chain. Make sure the safety chain does not touch lift chains or chain sheaves, tubes, hoses, fittings, or other parts on the mast. d. Lower the mast until there is tension in the safety chain, and the free-lift cylinder (free-lift and three-stage masts only) is completely retracted. If the engine is running, stop the engine. Apply the parking brake.

Install a DO NOT REMOVE tag on the safety chain(s). e. Install another safety chain (3/8 inch minimum) between the top or bottom crossmember of the carriage and a crossmember on the outer weldment.

3. Apply the parking brake. After lowering or restraining the mast, shut off the power and remove the key. Put a DO NOT OPERATE tag in the operator’s compartment. Disconnect the battery on electric lift trucks and put a tag or lock on the battery connector.

11

Maintenance Procedures Every 8 Hours or Daily

Figure 6. Two-Stage, Free-Lift, Three-Stage, and Four-Stage Masts

12

8000 SRM 772

8000 SRM 772

Maintenance Procedures Every 8 Hours or Daily Legend for Figure 6

1.

2.

3.

4.

OUTER WELDMENT INNER WELDMENT INTERMEDIATE WELDMENT FIRST INTERMEDIATE WELDMENT

Forks The identification of a fork describes how the fork is connected to the carriage. These lift trucks have hook-type forks.

Adjust The forks are connected to the carriage by hooks and lock pins. These lock pins are installed through the

5.

6.

7.

8.

HOOK FREE-LIFT CYLINDER CROSSMEMBER CROSSMEMBER

top fork hooks and fit into slots in the top carriage bar. See Figure 7. Adjust the forks as far apart as possible for the maximum support of the load. Hook forks will slide along the carriage bars to adjust for the load to be lifted. Raise the lock pin in each fork to slide the fork on the carriage bar. Make sure the lock pin is engaged in the carriage bar to lock the fork in position after the width adjustment is made.

A. EARLIER MODELS

B. LATER MODELS

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

FORKS CARRIAGE LOCK BACKREST EXTENSION FORK REMOVAL NOTCH LOCK PIN ASSEMBLY

LEVER WASHER SPRING PIN KNOB

Figure 7. Carriage and Forks

13

Maintenance Procedures Every 8 Hours or Daily

8000 SRM 772 Inspect

Remove

WARNING

WARNING

Do not try to move a fork without a lifting device. Each hook fork for these lift trucks can weigh 45 to 115 kg (100 to 250 lb).

Never repair damaged forks by heating or welding. Forks are made of special steel using special procedures. Replace damaged forks.

A fork can be removed from the carriage for replacement of the fork or other maintenance. Slide the fork to the fork removal notch on the bottom of the carriage bar. Lower the fork onto blocks so the bottom hook of the fork moves through the fork removal notch. See Figure 8. Lower the carriage farther so the top hook is disengaged from the top carriage bar.

Move the carriage away from the fork, or use a lifting device to move the fork away from the carriage.

Inspect the forks for cracks and wear. Check the alignment of the fork tips (Figure 9). The height of the fork tips must be within 3 percent of the length of each other. Some applications can require closer alignment.

Check that the bottom of the fork is not worn (Figure 9). Check the heel of the fork using fork tool. The heel of the fork must be 90 percent of dimension X; see Figure 9.

Replace any damaged or broken parts that are used to keep the forks locked in position.

Install

WARNING Do not try to move a fork without a lifting device. Each hook fork for these lift trucks can weigh 45 to 115 kg (100 to 250 lb).

1. CARRIAGE BARS 2. HOOK FORK

3. BLOCKS

Figure 8. Hook Fork Removal

14

Move the fork and carriage so the top hook on the fork can engage the upper carriage bar. Raise the carriage to move the lower hook through the fork removal notch. Slide the fork on the carriage so both upper and lower hooks engage the carriage. Engage the lock pin with a notch in the upper carriage bar.

8000 SRM 772

Maintenance Procedures Every 8 Hours or Daily

Fork Tip Alignment Length of Forks

3% Dimension

914 mm (36 in.)

1067 mm (42 in.)

1220 mm (48 in.)

1371 mm (54 in.)

1524 mm (60 in.)

27 32 37 40 46

1. TIP ALIGNMENT (MUST BE WITHIN 3% OF FORK LENGTH) 2. CRACKS 3. LATCH DAMAGE

mm mm mm mm mm

(1.10 (1.26 (1.46 (1.57 (1.81

in.) in.) in.) in.) in.)

4. HEEL OF FORK (MUST BE 90% OF DIMENSION X) 5. HEEL WEAR 6. FORK TOOL

Figure 9. Forks Check

Mast and Lift Chains WARNING When working on or near the mast or carriage, see Safety Procedures When Working Near Mast.

1. Inspect the welds on the mast and carriage for cracks. Make sure that the hex head bolts and nuts are tight.

2. Inspect the channels for wear in the areas where the rollers travel. Inspect the rollers for wear or damage.

3. Inspect the load backrest extension for cracks and damage.

4. Lubricate the lift chains with 30W engine oil.

The best procedure is to remove the chains from the lift truck and soak them in oil.

5. Inspect the lift chains for cracks or broken links and pins. See Figure 10.

6. Inspect the chain anchors and pins for cracks and damage.

15

Maintenance Procedures Every 8 Hours or Daily

8000 SRM 772 3. Remove the load from the forks. Check the clearance of the carriage when the mast is fully extended. The carriage stops must not touch the stop on the top crossmember of the inner weldment. The chains are too tight if the carriage touches the crossmember. Put the mast in a vertical position and lower the carriage completely.

If the forks do not just touch the surface, the chains are too tight. If the chains are too tight, adjust the chain anchors. Make sure each anchor is adjusted the same amount.

1.

2.

3.

4.

WORK PIN CRACKS EDGE WEAR HOLE WEAR

5. LOOSE LEAVES 6. DAMAGED PIN 7. CORROSION

Figure 10. Lift Chains Check 7. Make sure the lift chains are adjusted so they have equal tension. Adjustment or replacement of lift chains must be done by authorized personnel. See Lift Chain, Adjustment for adjustment procedures.

Lift Chain, Adjustment When correctly adjusted: • The tension will be the same on each chain of the chain set. Check tension by pushing on both chains at the same time.

• The chain length will be correct.

• The chains must travel freely through the complete cycle.

1. Put a load equal to 80 to 90 percent of the capacity load on the forks. Lower the forks as much as possible. Tilt the mast fully backward. See Figure 11.

2. Check the amount that the bottom carriage roller extends below the inner channel of the mast. The carriage roller must not extend more than 1/3 of the roller diameter below the inner channel. If the adjustment is not correct, adjust the chain anchors. Make sure each chain anchor is adjusted the same amount.

16

1.

2.

3.

4.

TILT MAST FULLY BACKWARD CARRIAGE ROLLER FORK CARRIAGE ROLLER MUST NOT EXTEND MORE THAN 34 mm (1.3 in.) BELOW INNER MAST CHANNEL Figure 11. Lift Chain Adjustments

NOTE: When the chain adjustments are complete, make sure that the threads on the nuts of the chain anchors are completely engaged. Make sure that the nuts on the chain anchors are not tight against the mountings. The chain anchors must be free to move in their sockets.

4. Three-stage mast chain adjustment: Adjust the main lift chains so the top of the inner weldment is even with the top of the intermediate weldment within ±1.5 mm (0.06 in.). Adjust the free-lift chain as described in Step 3.

8000 SRM 772

Maintenance Procedures Every 8 Hours or Daily

OPERATION CHECK

Service Brakes

Sit on the seat, turn the key switch to ON, and check the following operations: • Gauges and horn • Lift, tilt, and attachment functions • Service and parking brakes • Steering system • MONOTROL® pedal or the direction control lever and accelerator pedal

Loss of fluid from the master cylinder indicates a leak. Repair the brake system before the lift truck is used. Replace the brake fluid in the system if there is dirt, water, or oil in the system.

Gauges and Horn 1. Check the operation of the gauges and horn. The horn will operate when the key switch is OFF. The hourmeter will operate when the key switch is ON and the seat switch is closed.

WARNING Make sure the key switch is OFF and the park brake is set before connecting the battery.

2. The battery indicator will operate when the key switch is ON. If the battery is replaced with a fully charged battery, the battery indicator will not indicate a fully charged battery until the lift truck has operated for a short period of time.

Tilt the mast backward until the hydraulic relief valve operates. The battery indicator will then indicate correctly. A battery indicator without lift interrupt will only indicate battery charge when the hydraulic relief valve operates.

Control Levers and Pedals Check that the levers for the mast and attachment operate as described in Tables 1 and 3 of the Operating Manual. Check that the brake operates as described in Table 1 of the Operating Manual.

WARNING

Check the operation of the service brakes. See Maintenance Schedule. Push on the brake pedal. The brakes must be applied before the pedal reaches the floor plate. The brake pedal must stop firmly and must not move slowly down after the brakes are applied. The brakes must apply equally to both drive wheels with no noticeable pull to either side.

Parking Brake Check the operation of the parking brake. The parking brake, when in good condition and correctly adjusted, will hold the lift truck with a capacity load on a 15 percent grade [a slope of 1.5 m in 10 m (1.5 ft in 10 ft)]. See the adjustment procedure under Maintenance Procedures Every 2000 Hours or Yearly, Brakessection of this manual.

Steering System WARNING The steering can be difficult when the power steering pump is not operating.

Check that the steering system operates smoothly and gives good steering control.

17

Maintenance Procedures Every 350 Hours or 3 Months

8000 SRM 772

Maintenance Procedures Every 350 Hours or 3 Months NOTE: Do these procedures in addition to the 8-hour checks.

Tighten the seven capscrews retaining the steering trunion to the lift truck frame to 86 N•m (63 lbf ft).

The capscrews are located in the rear compartment.

HYDRAULIC TANK BREATHER The hydraulic tank breather is a part of the dipstick for the hydraulic tank. Remove the dipstick and clean the breather portion of the dipstick. Replace the dipstick when the breather is dirty and will not permit the easy passage of air. See Figure 3.

WHEEL NUT TORQUE Tighten wheel nuts as required. See Install Wheel and Tire.

TRANSAXLE Each transaxle has its separate oil supply. See Figure 12. Make certain the lift truck is parked in a level area. Remove the level plug to check the level of the oil. The oil should be level with the bottom of the level hole. If it is necessary to add oil, remove the fill plug and add the oil through the fill plug until the oil starts to run out of the oil level hole. Replace both the oil level plug and the fill plug.

Make certain to check both transaxles.

STEERING ACTUATOR MOUNTING BOLTS WARNING To avoid personal injury and prevent electrical shock or damage to the equipment, disconnect the battery and separate the connector before opening the compartment cover or inspecting/repairing the electrical system.

The capacitor in the traction motor controller can hold an electrical charge after the battery is disconnected. Discharge the capacitor before inspecting or repairing any component.

Wear safety glasses.

1. Block the lift truck so the drive wheels are off the floor. See How to Put Lift Truck on Blocks.

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

3. Discharge the capacitors in the controllers by connecting a 200-ohm, 2-watt resistor across the controller’s POS and NEG terminals (outer two power cable terminals). See Figure 16 and Figure 17. 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.

18

1. FILL PLUG 2. LEVEL PLUG

3. DRAIN PLUG 4. BREATHER

Figure 12. Transaxle Lubrication Points

8000 SRM 772

LIFT SYSTEM OPERATION WARNING

Maintenance Procedures Every 350 Hours or 3 Months

MAST WARNING

When working on or near the mast or carriage, see Safety Procedures When Working Near Mast located in Maintenance Procedures Every 8 Hours or Daily.

When working on or near the mast or carriage, see Safety Procedures When Working Near Mast located in Maintenance Procedures Every 8 Hours or Daily.

Lower the lift mechanism completely. Never allow anyone under a raised carriage. Do not put any part of your body in or through the lift mechanism unless all parts of the mast are completely lowered and the key switch is OFF.

Do not work under a raised carriage. Lower the carriage or use a safety chain to prevent the carriage from lowering when doing maintenance on the mast and lift chains.

Do not try to locate hydraulic leaks by putting hands on pressurized hydraulic components.

Hydraulic oil can be injected into the body by pressure.

1. Check for leaks in the hydraulic system. Check the condition of the hydraulic hoses and tubes.

NOTE: Parts of the mast move at different speeds during raising and lowering.

2. Slowly raise and lower the mast several times without a load. The mast components must raise and lower smoothly in the correct sequence. The carriage raises first, then the inner weldment and the intermediate weldment (three-stage masts only).

3. The inner weldment(s) and the carriage must lower completely.

4. Raise the mast 1 m (3 ft), with a capacity load.

The inner weldment(s) and carriage must raise smoothly. Lower the mast. All moving components must lower smoothly.

5. With the load lowered, tilt the mast backward and forward. The mast must tilt smoothly and both tilt cylinders must stop evenly.

Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the recommendations of the manufacturer.

Be careful when cleaning with steam. Steam can cause serious burns. Wear protective clothing, eye protection, and gloves. Never expose your skin to steam.

CAUTION DO NOT use steam or high-pressure water to clean the load rollers or the lift chains. Steam and high-pressure water can remove the lubrication from the bearings in the load rollers.

Water in the bearings of the sheaves and the link pins of chains can also shorten the service life of these parts.

1. Lubricate the sliding surfaces and the load roller surfaces along the full length of the channels as shown in Figure 13 and Figure 14. Apply lubricant only to the indicated surfaces.

NOTE: The load rollers and sheaves have sealed bearings that do not need additional lubrication.

2. Lubricate the mast pivots with multipurpose grease at the grease fittings on the pivot pins.

6. Check that the controls for the attachment operate the functions of the attachment. (See symbols by each of the controls.) Make sure all of the hydraulic lines are connected correctly and do not leak.

19

Maintenance Procedures Every 350 Hours or 3 Months

8000 SRM 772

A. UPPER LOAD ROLLERS B. LOWER LOAD ROLLERS 1. LUBRICATE STRIP BEARINGS SURFACES 2. LUBRICATE SURFACES WHERE LOAD ROLLERS TRAVEL 3. LOAD ROLLER Figure 13. Mast Lubrication

NOTE: TYPICAL MAST SHOWN. 1. OUTER WELDMENT 2. INNER WELDMENT 3. FREE-LIFT CHAIN 4. FREE-LIFT CYLINDER

5. MAIN LIFT CYLINDER 6. LOWERING CONTROL VALVE (EXTERNAL)

Figure 14. Two-Stage Mast With Full Free Lift

20

8000 SRM 772

Maintenance Procedures Every 350 Hours or 3 Months

LIFT CHAINS WARNING When working on or near the mast or carriage, see Safety Procedures When Working Near Mast located in Maintenance Procedures Every 8 Hours or Daily.

Do not work under a raised carriage. Lower the carriage or use a safety chain to prevent the carriage from lowering when doing maintenance on the mast and lift chains.

1. Lubricate the lift chains with 30W engine oil.

The best procedure is to remove the chains from the lift truck and soak them in oil.

2. If a section of chain is 3 percent longer than a similar section of new chain, the chain is worn and must be replaced. If a chain scale is available, check the lift chains as shown in Figure 15.

If a chain scale is not available, measure 20 links of chain. Measure from the center of a pin to the center of another pin 20 pitches away. Compare the length with the chart in Figure 15. Replace the chain if the length of 20 links of the worn section is more than the maximum wear limit.

Pitch

12.7 mm (0.50 in.)

15.9 mm (0.63 in.)

19.1 mm (0.75 in.)

25.4 mm (1.00 in.)

31.8 mm (1.25 in.)

44.5 mm (1.75 in.)

50.8 mm (2.00 in.)

Wear Limit Total length of The maximum 20 links (pitch) length of 20 of new chain links.

254.0 mm (10.0 in.)

317.5 mm (12.5 in.)

381.0 mm (15.0 in.)

508.0 mm (20.0 in.)

635.0 mm (25.0 in.)

889.0 mm (35.0 in.)

1016.0 mm (40.0 in.)

261.6 mm (10.3 in.)

327.0 mm (12.9 in.)

392.4 mm (15.4 in.)

523.3 mm (20.6 in.)

654.1 mm (25.75 in.)

915.7 mm (36.05 in.)

1046.5 mm (41.2 in.)

NOTE: THE INSTRUCTIONS FOR MEASURING CHAIN WEAR ARE SHOWN ON THE CHAIN WEAR SCALE. 1. CHAIN WEAR SCALE Figure 15. Lift Chains Check

21

Maintenance Procedures Every 350 Hours or 3 Months

FORKS WARNING Never repair damaged forks. Do not heat, weld, or bend the forks. Forks are made of special steel using special methods. Replace damaged forks.

Do not try to move a fork without a lifting device. Each hook fork for these lift trucks can weigh 45 to 115 kg (100 to 250 lb).

1. Check the heel and attachment points of the forks with a penetrant or magnetic particle inspection. See Figure 7, Figure 8, and Figure 9.

2. Inspect the forks for cracks and wear. Check the alignment of the fork tips ( Figure 9). The height of the fork tips must be within 3 percent of the length of each other. Some applications can require closer alignment. Check the fork for wear.

Dimension 4, Figure 9, must be at least 90 percent at dimension X.

SAFETY LABELS WARNING Safety labels are installed on the lift truck to give information about operation and possible hazards. It is important that all safety labels are installed on the lift truck and can be read.

Make sure that the safety labels are clearly readable.

Install new and correct labels if necessary. For installation instructions, see the section Frame 100 SRM 775.

BRAKE FLUID WARNING Loss of fluid from the master cylinder indicates a leak. Repair the brake system before the lift truck is used. Replace the brake fluid in the system if there is dirt, water, or oil in the system.

22

8000 SRM 772 Check the brake fluid in the reservoir for the master cylinder. Add brake fluid as necessary. Use the brake fluid shown in the Maintenance Schedule.

OTHER LUBRICATION Lubricate hinges, pins, linkages, cables, pedals, and levers as necessary. Use SAE 30 oil, multipurpose grease, or silicone spray lubricant (Hyster part number 328388) as needed. See the Maintenance Schedule.

ELECTRICAL INSPECTION Special Precautions WARNING To avoid personal injury and prevent electrical shock or damage to the equipment, disconnect the battery and separate the connector before opening the compartment cover or inspecting/repairing the electrical system.

The capacitor in the traction motor controller can hold an electrical charge after the battery is disconnected. Discharge the capacitor before inspecting or repairing any component.

Wear safety glasses.

1. Block the lift truck so the drive wheels are off the floor. See How to Put Lift Truck on Blocks.

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

3. Discharge the capacitors in the controllers by connecting a 200-ohm, 2-watt resistor across the controller’s POS and NEG terminals (outer two power cable terminals). See Figure 16 and Figure 17. 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.

8000 SRM 772

Maintenance Procedures Every 350 Hours or 3 Months

Contactors WARNING Disconnect the battery connector to prevent injury from electric shock before you make any inspections or repairs. Attach a tag to the connector that states, DO NOT CONNECT.

WARNING Before troubleshooting, adjusting, or connecting or disconnecting the handset, perform the following: 1. Turn the key switch to the OFF position and unplug the battery.

2. Discharge the capacitors by connecting a 200-ohm 2-watt resistor between the positive standoff and the negative standoff.

WARNING 1.

2.

3.

4.

NEGATIVE POWER CABLE CONNECTION POSITIVE POWER CABLE CONNECTION 200-OHM, 2-WATT RESISTOR INSULATED JUMPER WIRES Figure 16. Discharging Capacitors, Earlier Models

Make sure the key switch is OFF and the park brake is set before connecting the battery.

The contact surfaces are silver alloy on a copper base. In normal operation, the contact surfaces become rough and black. Cleaning is not necessary. Do not use a file or emery cloth on the contacts. Replace the contacts when the surface wears through to the copper base. Always replace the contacts in sets.

Check for equal spring tension if the contacts do not wear evenly. See Figure 18, Figure 19, Figure 20., Figure 21, Figure 22, and Figure 23.

Motor Brushes

1.

2.

3.

4.

POSITIVE CONNECTION NEGATIVE CONNECTION JUMPER WIRES 200-OHM, 2-WATT RESISTOR

1. Visually inspect the commutator and brushes every 350 hours on all electric lift trucks. Make sure the surface of the commutator is not streaked, grooved, or damaged and that the operation of the motor is correct. Worn motor brushes must be replaced before they damage the surface of the commutator. Move the brush spring to remove a brush from the brush holder.

When the brush wears within approximately 1.5 mm (0.060 in.) of where the brush wire joins the brush, the brush must be replaced. For the traction motors, the minimum brush length is 21.5 mm (0.845 in.). For the hydraulic motor, the minimum brush length is 15.9 mm (0.625 in.).

Figure 17. Discharging Capacitors, Later Models

23

Maintenance Procedures Every 350 Hours or 3 Months 2. Inspect the brush holders for burns or damage.

Make sure the brush holder is fastened tightly to the mountings at the end of the motor. Make sure the brushes will move freely and smoothly in the brush holders.

3. Check the brush springs for damage from heat and corrosion. Replace a damaged brush spring.

See the section DC Motor Maintenance 620 SRM 294 for additional information for repair and replacement of the commutator and brushes.

1.

2.

3.

4.

LEFT TRACTION MOTOR CONTROLLER LIFT PUMP MOTOR CONTROLLER LIFT PUMP, MOTOR FUSE KEY SWITCH, TRACTION CONTROLLERS AND AUXILIARY FUSES

8000 SRM 772

Parking Brake 1. Lubricate the pushpins, the bore of the caliper body caliper lever, and caliper lever washer using antiseize Hyster P/N 251979 or equivalent. See Figure 24.

2. Coat all other mating surfaces of the brake linkage with multipurpose grease.

3. Inspect the brake cable for damage or fraying.

5.

6.

7.

8.

9.

LINE CONTACTOR POWER STEER PUMP MOTOR FUSE POWER STEERING CONTACTOR RIGHT TRACTION MOTOR CONTROLLER TRACTION FUSE

Figure 18. Electrical Compartment With Transistor-Controlled Lift Pump

24

8000 SRM 772

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

Maintenance Procedures Every 350 Hours or 3 Months

LEFT TRACTION MOTOR CONTROLLER SENSOR INTERFACE/CONTACTOR DRIVER MODULE LIFT PUMP CONTACTOR LIFT PUMP MOTOR FUSE KEY SWITCH, TRACTION CONTROLLERS AND AUXILIARY FUSES LINE CONTACTOR POWER STEER PUMP MOTOR FUSE POWER STEERING CONTACTOR RIGHT TRACTION MOTOR CONTROLLER TRACTION FUSE Figure 19. Electrical Compartment With One-Speed Lift Pump

25

Maintenance Procedures Every 350 Hours or 3 Months

1. LEFT TRACTION MOTOR CONTROLLER 2. SENSOR INTERFACE/CONTACTOR DRIVER MODULE 3. LIFT PUMP CONTACTOR 4. LIFT PUMP MOTOR FUSE 5. KEY SWITCH, TRACTION CONTROLLERS, AND AUXILIARY FUSES

8000 SRM 772

6.

7.

8.

9.

10.

LINE CONTACTORS POWER STEER PUMP MOTOR FUSE POWER STEERING CONTACTOR RIGHT TRACTION MOTOR CONTROLLER TRACTION FUSE

Figure 20. Electrical Compartment With Two-Speed Lift Pump

26

8000 SRM 772

Maintenance Procedures Every 350 Hours or 3 Months Legend for Figure 21 1. ENCLOSURE SHROUD 2. CAPSCREW 3. INSULATOR 4. FIXED CONTACT 5. CAPSCREW 6. COVER

7.

8.

9.

10.

11.

RETURN SPRING MOVING CONTACT BASE PLUNGER COIL AND FRAME

Figure 21. Typical EE Contactor

27

Maintenance Procedures Every 350 Hours or 3 Months

1.

2.

3.

4.

5.

6.

7.

8.

BASE COIL FRAME CONTACT CONTACT CLAMP SPRING ARMATURE

8000 SRM 772

9.

10.

11.

12.

13.

14.

15.

BASE CARRIER BUSHING CONTACT SPRING SEAT SPRING RETAINER

Figure 22. Typical Contactor

28

8000 SRM 772

1.

2.

3.

4.

5.

6.

7.

Maintenance Procedures Every 350 Hours or 3 Months

LOCKWASHER CAPSCREW CONTACTOR DRIVER MODULE LOCKWASHER WASHER SCREW STUD

8.

9.

10.

11.

12.

13.

14.

LOCKWASHER NUT BASEPLATE CONTACTOR WASHER SCREW POWER CABLE

Figure 23. Pump Contactor Panel, EE

29

Maintenance Procedures Every 2000 Hours or Yearly

1.

2.

3.

4.

5.

6.

7.

8.

CARRIER SIDE DISC PAD CAM SIDE DISC PAD BACKUP PLATE PUSH PIN SPRING COTTER PIN

8000 SRM 772

9.

10.

11.

12.

13.

14.

15.

NUT WASHER LEVER HEX HEAD BOLT BUSH NUT SPACER

Figure 24. Parking Brake Caliper

Maintenance Procedures Every 2000 Hours or Yearly NOTE: Do these procedures in addition to the 8-hour and 350-hour checks.

HYDRAULIC SYSTEM

Remove the hydraulic oil strainer located in the feed line to the hydraulic power steering pump. Remove the clamp and remove the hose from the pump to access the strainer. Clean the strainer. If the strainer cannot be cleaned, it should be replaced.

Hydraulic Oil Filter, Change Replace the filter element after the first 50 hours of operation on a new lift truck. Replace the oil filter every 2000 hours or yearly after the first 50 hours.

Remove the spin-on oil filter and replace it with a new filter. Clean the breather on the dipstick. See Figure 3.

Hydraulic Oil Strainer, Check Remove the hydraulic oil strainer located on top of the hydraulic tank. Clean the strainer. If the strainer cannot be cleaned, it should be replaced.

30

Hydraulic Oil, Change WARNING The hydraulic oil can be hot. Be careful when you drain the hydraulic oil.

Put the lift truck on a level surface. Lower the mast.

Put a drip tray with a minimum of 27.5 liter (29 qt) capacity under the hydraulic tank. Remove the drain plug on the bottom of the hydraulic tank and drain the hydraulic oil.

8000 SRM 772 When the oil has drained, install the drain plug. Fill the hydraulic tank with the oil described in the Maintenance Schedule.

BRAKES Check the brake pads and discs for wear. Minimum thickness of service brake pads is 0.76 mm (0.03 in.).

Minimum thickness of cam side parking brake pad is 6.60 mm (0.26 in.). Minimum thickness of brake disc is 3.6 mm (0.142 in.).

Check the operation of the service brakes and the parking brake. See the repair procedures described in the section Brake System 1800 SRM 570.

There is no adjustment for the service brakes.

Replace the parking brake cable. See the repair procedures described in the section Brake System 1800 SRM 570.

Parking Brake, Adjust WARNING To access the parking brakes, the mast and carriage must be raised and a safety chain installed. See Safety Procedures When Working Near Mast.

NOTE: The parking brake calipers must be adjusted before any other brake adjustments are made.

The parking brake may be adjusted in three different locations. Before making any adjustments, park the lift truck in a level area and block the wheels. Release the parking brake lever.

1. Check to make certain that the brake pads are contacting the brake disc evenly. If the brake pads are not contacting the disc evenly, remove the cotter pin and tighten the castle nut until the brake pads just contact the brake disc. Back off on the castle nut until the cotter pin can be installed. Adjust the parking brake caliper as follows: a. Lubricate the pushpins, the bore of the caliper body, caliper lever, and caliper lever washer using antiseize Hyster P/N 251979 or equivalent. See Figure 24. Refer to Maintenance Schedule. b. Coat all other mating surfaces of the brake linkage with multipurpose grease. See Figure 25.

Maintenance Procedures Every 2000 Hours or Yearly c. Remove the cotter pins from the castle nuts.

Torque the castle nuts to 1.5 N•m (13 lbf in). d. Back off on the castle nut by four flats (240 degrees). e. Check the clearance between the brake pad and brake disc. The clearance between the brake pad and disc must be 0.30 to 0.38 mm (0.012 to 0.015 in.). f.

Install new cotter pins to retain the castle nuts. If the nut must be moved to provide access to install the cotter pin, the castle nut should be tightened.

g. Install the yoke end pins to attach the yokes to the cam levers. Install new cotter pins to retain the yoke end pins.

2. The length of the brake cable can be adjusted at the end of the cable connected to the bracket located at the bottom of the cowl. To adjust the length of the cable, remove the jam nut retaining the ball stud to the brake bracket. Loosen the jam nut on the end of the ball stud retaining the ball stud. Turn the ball stud clockwise to decrease the length of the brake cable. Turn the ball stud counterclockwise to increase the length of the cable. Decreasing the cable length will increase the brake pressure. When increasing the cable length, the minimum thread engagement of the cable into the ball stud is 12 mm (0.47 in.).

3. The other adjustment can be made by removing the cotter pin and the clevis pin, retaining the rod ends to the brake levers. Lengthen or shorten the rod ends as required. Turn the rod ends clockwise to shorten the length of the rod end and to increase the braking capability. Install the clevis pin and the cotter pin after the proper adjustment has been made. Both rod ends should be adjusted equally.

4. Test the operation of the parking brake. The parking brake, when in good condition and correctly adjusted, will hold a lift truck with a capacity load on a 15 percent grade [a slope of 1.5 m in 10 m (1.5 ft in 10 ft)].

TRANSAXLE Each transaxle has its separate oil supply. See Figure 12. Raise the mast and safety chain to access the transaxle assemblies. Place a pan with at least a 3.8 liter (1 gal) capacity under the transaxles.

31

Maintenance Procedures Every 2000 Hours or Yearly

8000 SRM 772

Remove the drain, check and fill plugs on each transaxle. After both transaxles have drained completely, replace the drain plugs and torque to the specification as shown in Table 2. Fill the transaxles

with the oil described in the Maintenance Schedule.

See the repair procedures described in the section Transaxle Assembly 1300 SRM 568.

Table 2. Transaxle Specifications Weight

80 kg (177 lb)

Gear Ratio

15:61:1

Gear Oil Capacity

1.18 liter (0.31 gal)

Drain Plug

22 N•m (16 lbf ft)

1.

2.

3.

4.

PARKING BRAKE ASSEMBLY BRACKET BRAKE RELEASE LEVER BALL STUD

5.

6.

7.

8.

SPRING BELLCRANK BRAKE RODS BRAKE CABLE

9. PLATE ASSEMBLY 10. SWITCH 11. CAM BLOCK

Figure 25. Parking Brake Arrangement

32

8000 SRM 772

Lift and Tilt System Leak Check

Maintenance Procedures Every 4000 Hours NOTE: Do these procedures in addition to the 8-hour, 350-hour, and 2000-hour checks.

TRANSAXLE WARNING Care must be taken during greasing of the outer pinion bearing. If grease is allowed to remain on the exterior of the transaxle assembly or drive motor, the grease may contaminate the disc brake system and cause brake system malfunction. Personal injury or property damage can result if the brake system fails.

Apply multipurpose grease with 2 to 4 percent molybdenum disulfide (Hyster P/N 328388 or equivalent) with a high-pressure gun to each transaxle outer pinion bearing grease fitting. Clean lube fitting and relief hole before and after lubricating.

The transaxle fitting is located behind each drive tire. Drive tire removal is necessary to access the fittings. Refer to Wheels and Tires Maintenance, Remove Wheel From Lift Truck for drive tire removal instructions.

Lift and Tilt System Leak Check LIFT SYSTEM WARNING When working on or near the mast or carriage, see Safety Procedures When Working Near Mast located in Maintenance Procedures Every 8 Hours or Daily.

Never allow anyone under a raised carriage.

Do not put any part of your body in or through the lift mechanism unless all parts of the mast are completely lowered, the key is removed, and the battery is disconnected.

Do not try to find hydraulic leaks by putting hydraulic components under pressure. Hydraulic oil can be injected into the body by pressure.

During the test procedures for the hydraulic system, fasten the load to the carriage with chains to prevent it from falling. Keep all personnel away from the lift truck during the tests.

1. Operate the hydraulic system. Put a capacity load on the forks, and raise and lower the load several times. Lower the load, and tilt the mast

forward and backward several times. Check for leaks.

2. Raise the carriage and the load 1 m (3 ft). If the carriage lowers slowly with the control valve in a neutral position, there are leaks inside the hydraulic system. The maximum speed that the carriage is allowed to lower is 50 mm (2 in.) per 10 minutes when the hydraulic oil is 30 C (90 F).

If the oil temperature is 70 C (160 F), the maximum speed that the carriage can lower is 150 mm (6 in.) per 10 minutes.

3. Check the lift cylinder for internal leaks. Remove the load from the forks. Install a gate valve in the supply line between the main control valve and the mast. Put a capacity load on the forks again.

Raise the carriage 1 m (3 ft). Close the gate valve.

If the carriage or mast weldments lower slowly, the seals in the lift cylinders have leaks.

4. If the carriage does not move, open the gate valve and check for movement again. If the carriage lowers when the valve is open, check for leaks in the hydraulic lines or fittings. If no leaks are found, the main control valve might be damaged.

Remove the load from the forks.

33

Battery Maintenance

8000 SRM 772

TILT SYSTEM WARNING When working on or near the mast or carriage, see Safety Procedures When Working Near Mast located in Maintenance Procedures Every 8 Hours or Daily.

Never allow anyone under a raised carriage.

Do not put any part of your body in or through the lift mechanism unless all parts of the mast are completely lowered, the key is removed, and the battery is disconnected.

Do not try to find hydraulic leaks by putting hydraulic components under pressure. Hydraulic oil can be injected into the body by pressure.

During the test procedures for the hydraulic system, fasten the load to the carriage with chains to prevent it from falling. Keep all personnel away from the lift truck during the tests.

1. Put a capacity load on the forks. Slowly tilt the mast forward. If the mast continues to slowly

tilt forward when the control valve is in a neutral position, there are leaks inside the hydraulic system. The maximum speed that the mast is allowed to tilt forward when there are internal leaks in the lift system is 13 mm (0.50 in.) per 10 minutes (measured at the tilt cylinder). This maximum speed is measured when the hydraulic oil is 30 C (90 F). If the oil temperature is 70 C (160 F), the maximum speed is 39 mm (1.5 in.) per 10 minutes.

2. If the leak rate is greater than specifications, remove the load from the mast. Install a valve between the port at the front of the tilt cylinder and the hydraulic line. Put the load on the forks again. Close the valve. If the mast tilts slowly forward, the cylinder seals are leaking. Be sure to check both tilt cylinders.

3. If the mast does not move, open the gate valve and check for movement again. If the mast moves forward when the gate valve is open, check for leaks in the hydraulic lines or fittings.

If no leaks are found, the main control valve might be damaged. Remove the load from the forks.

Battery Maintenance HOW TO CHARGE BATTERY WARNING If the lift truck was operated with a low battery, check all contactors for welded contacts before a charged battery is connected.

Make sure the key switch is OFF and the park brake is set before connecting the battery.

The acid in the electrolyte can cause injury.

Use water to flush the area and make the acid neutral with a water and soda solution. Acid in the eyes must be flushed with water. Batteries generate explosive fumes when they are being charged. Keep fire, sparks, and burning material away from the battery charger area. Avoid sparks from the battery connections. Charge batteries only in the special area for charging batteries. When the battery is being charged, keep the vent caps clear. The battery charger area must have ventilation so explosive fumes

34

are removed. Open the battery cover on a covered battery. Disconnect the battery when doing cleaning and maintenance.

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. See Figure 26.

Follow 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). Never charge a battery at a rate that will raise the electrolyte temperature above 49 C (120 F). Never let a battery stay discharged for long periods.

8000 SRM 772

Battery Maintenance

NORMAL CHARGE: This is the charge that is normally given to a battery that is discharged from normal service. Many users give this charge at a regular interval based on usage. This practice will keep the battery fully charged if the battery is not discharged below the limit. Always use a hydrometer to check the battery if the interval charge cycle is used. Frequent charging of a battery that has a 2/3 or more charge can decrease battery life.

Do NOT give an equalizing charge more than once a week. The most accurate specific gravity measurements for a charged battery will be after an equalizing charge. If the specific gravity difference is more than 0.020 between cells of the battery after an equalizing charge, there can be a defective cell.

Consult your battery dealer.

Also see the section Industrial Battery 2240 SRM 1 for additional information on the charging and maintenance of a battery.

NOTE: Many users 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.

HOW TO CHANGE 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.

Specific Gravity Reading

Electrolyte Temp.

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)

+0.001 or value.

Correction Points

0.004

Correct Value

1.206

0.001 for each 2 C from the 25 C base

Figure 26. Battery Check EQUALIZING CHARGE: 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.

Batteries are heavy. Use care to avoid injury.

The replacement battery must fit the battery area correctly. Use spacers to prevent the battery from moving in the battery compartment.

Make sure the weight of the replacement battery is within the maximum and minimum weights shown on the Nameplate.

WARNING Make sure the key switch is OFF and the park brake is set before connecting the battery.

1. Disconnect the battery. Move the steering wheel to its top position. Move the seat backward to its rear adjustment position. See Figure 27.

35

Battery Maintenance

8000 SRM 772 2. Release the hydraulic control cover, and raise the hydraulic controls and the cover for access to the hood latch. Disengage the hood latch and raise the battery cover. The gas-filled, double-dampened strut will help raise the hood and hold the battery cover in the open position for access to the battery.

3. Move the connector and cables so they will not be damaged when the battery is moved.

4. Use a spreader bar and crane to lift the battery from the lift truck. When a replacement battery is installed, make sure the battery is the correct size and weight for the lift truck. See the Nameplate.

Figure 27. Changing Battery

BATTERY SIZE SPECIFICATIONS Table 3. Battery Size Specifications - Type: Lead-Acid Battery Maximum Battery Compartment Size 1 Width

Length

Voltage

Height

Maximum Battery Size Width

Length

Height 2

Battery Weight

Battery Spacers

Range

Division

J30XMT2 TRUCK CAPACITY 1361 kg (3000 lb) - WHEEL BASE 1385 mm (54.5 in.)

990 mm (39 in.)

546 mm (21.5 in.)

48

970 mm 531 mm (38.2 in.) (20.9 in.)

579 mm (22.8 in.)

930 to 1027 kg (2050 to 2265 lb)

2031110

36

983 mm 518 mm (38.7 in.) (20.4 in.)

579 mm (22.8 in.)

896 to 991 kg (1975 to 2185 lb)

2031110

673 mm (26.5 in.)

WARNING The battery must fit the battery compartment so the battery restraint system will operate correctly. Use the spacers designed by the Hyster Company to prevent the battery from moving more than 13 mm (0.5 in.) in any horizontal direction.

NOTE: Maximum tolerances are ±3 mm (±0.12 in.) for the size of the battery compartment. The battery specification table shows the maximum size tolerances that will permit the battery to still fit into the battery compartment.

1 2

Dimensions are for the battery compartment with the required platform and acid tray installed.

The battery heights listed in this table are the height of the battery from the bottom of the battery to the top of the cells.

36

8000 SRM 772

Battery Maintenance

Table 3. Battery Size Specifications - Type: Lead-Acid Battery (Continued) Maximum Battery Compartment Size 1 Width

Length

Voltage

Height

Maximum Battery Size Width

Length

Height 2

Battery Weight

Battery Spacers

Range

Division

J35XMT2 TRUCK CAPACITY 1588 kg (3500 lb) - WHEEL BASE 1495 mm (58.8 in.)

990 mm (39 in.)

640 mm (25.2 in.)

48

980 mm 600 mm (38.6 in.) (23.6 in.)

579 mm (22.8 in.)

1052 to 1186 kg (2320 to 2615 lb)

2014631

36

983 mm 632 mm (38.7 in.) (24.9 in.)

579 mm (22.8 in.)

1109 to 1227 kg (2445 to 2705 lb)

2014631

673 mm (26.5 in.)

J40XMT2 TRUCK CAPACITY 1814 kg (4000 lb) - WHEEL BASE 1495 mm (58.8 in.)

990 mm (39 in.)

640 mm (25.2 in.)

48

980 mm 600 mm (38.6 in.) (23.6 in.)

579 mm (22.8 in.)

1052 to 1186 kg (2320 to 2615 lb)

2014633

36

983 mm 632 mm (38.7 in.) (24.9 in.)

579 mm (22.8 in.)

1109 to 1227 kg (2445 to 2705 lb)

2014633

673 mm (26.5 in.)

WARNING The battery must fit the battery compartment so the battery restraint system will operate correctly. Use the spacers designed by the Hyster Company to prevent the battery from moving more than 13 mm (0.5 in.) in any horizontal direction.

NOTE: Maximum tolerances are ±3 mm (±0.12 in.) for the size of the battery compartment. The battery specification table shows the maximum size tolerances that will permit the battery to still fit into the battery compartment.

1

Dimensions are for the battery compartment with the required platform and acid tray installed.

2

The battery heights listed in this table are the height of the battery from the bottom of the battery to the top of the cells.

37

Wheels and Tires Maintenance

8000 SRM 772

Wheels and Tires Maintenance GENERAL WARNING A solid rubber tire that is the same shape as a pneumatic tire can be installed on a rim for a pneumatic tire. DO NOT make changes in the parts of the rim if a solid rubber tire is installed instead of a pneumatic tire.

The lift truck capacity can change with different types of tires. Make sure the capacity on the Nameplate is for the type of tires installed.

The type of tire and the air pressure (pneumatic tires) are shown on the Nameplate. Make sure the Nameplate is correct for the type of tires on the lift truck.

The J30XMT2, J35XMT2, and J40XMT2 series of lift trucks use pneumatic tires or pneumatic-shaped solid tires. Do not mix types of tires or tread on the lift truck.

HOW TO CHANGE TIRES WARNING A solid rubber tire that is the same shape as a pneumatic tire can be installed on a rim for a pneumatic tire. DO NOT make changes in the parts of the rim if a solid rubber tire is installed instead of a pneumatic tire.

The lift truck capacity can change with different types of tires. Make sure the capacity on the Nameplate is for the type of tires installed.

The type of tire and the air pressure (pneumatic tires) are shown on the Nameplate. Make sure the Nameplate is correct for the type of tires on the lift truck.

WARNING Wheels must be changed and tires replaced by trained personnel only. Always wear safety glasses.

38

See the WARNING about How to Put Lift Truck on Blocks at the beginning of this section.

See How to Raise Drive Tires or How to Raise Steer Tires at the beginning of this section.

The tire sizes and the standard tire pressures are listed for both drive and steering tires. Trucks equipped with special tires and/or used on special applications may require different tire pressures.

Consult your nearest authorized Hyster dealer.

STEER AND DRIVE WHEELS WARNING If the tire has less then 80 percent of recommended inflated pressure, the tire must be removed before air is added. Put the tire in a safety cage when adding air pressure to the tire. Disassemble the rim and inspect all parts for damage. Do not use any damaged or repaired wheel parts. Do not repair any parts of the wheel. Always replace damaged parts. Do not mix parts between different types of wheel assemblies.

Observe previous warning before working on steer or drive wheels. See Figure 28.

PNEUMATIC TIRES Remove Wheel From Lift Truck WARNING Wheels must be changed and tires repaired by trained personnel only. Always wear safety glasses. Deflate tire completely before removing the wheel from the lift truck. Air pressure in the tires can cause the tire and rim parts to explode, causing serious injury or death.

1. Loosen the wheel lug nuts. See the WARNING about How to Put Lift Truck on Blocks at the beginning of this section.

8000 SRM 772

Wheels and Tires Maintenance

A. PNEUMATIC TIRE AND PNEUMATIC-SHAPED SOLID TIRES

B. THREE-PIECE WHEEL

1.

2.

3.

4.

5. LOCK RING 6. SIDE FLANGE 7. WHEEL RIM

PNEUMATIC TIRE FLAP VALVE WASHER PNEUMATIC-SHAPED SOLID TIRE

Figure 28. Types of Wheels

WARNING Make sure all of the air pressure is removed from the tire before a wheel is disassembled.

Air pressure in the tires can cause the tire and rim parts to explode, causing serious injury or death. Keep tire tools in firm contact with the wheel parts. If the tool slips, it can move with enough force to cause an injury.

2. Remove the air from the tire. Remove the valve core to make sure that all of the air is out of the inner tube. Push a wire through the valve stem to make sure that the valve stem does not have a restriction.

Tire Sizes and Pressures J30XMT2 and J35XMT2

Tire Size

kPa

psi

18 × 7-8 (16PR)

1000

145

18 × 7-8

NA

NA

DRIVE TIRES Pneumatic PneumaticShaped Solid

STEER TIRES Pneumatic

15 × 4.5 × 8 (12PR)

1000

145

PneumaticShaped Solid

15 × 4.5 × 8

NA

NA

kPa

psi

NA

NA

NA

NA

WARNING The lifting and carrying of pneumatic tires is not recommended because their weight could be in excess of 45 kg (100 lb). Where applicable, use a wheel or tire dolly to assist in the removal and installation of the wheel.

3. Remove the wheel lug nuts, and remove the wheel and tire from the lift truck. Lift truck tires and wheels are heavy.

J40XMT2

Tire Size DRIVE TIRES

PneumaticShaped Solid

200/50 × 10 STEER TIRES

PneumaticShaped Solid

15 × 4.5 × 8

39

Wheels and Tires Maintenance

Remove Tire From Wheel STEP 1.

Loosen the tire bead from the side flange.

STEP 2.

Put the tire tool into the slot between the lock ring and wheel rim. Remove the lock ring and side flange.

If there is a flange seat, remove it.

STEP 3.

Loosen the bead from the other side of the wheel rim.

Remove the valve stem from the wheel.

STEP 4.

Remove the wheel from the tire.

40

8000 SRM 772

8000 SRM 772

Wheels and Tires Maintenance

Install Tire on Wheel WARNING Wheels can explode and cause injury or death if the following procedures are not followed: • Clean and inspect all parts of the wheel before installing the tire. Paint any parts that have rust or corrosion.

• Do NOT use any damaged or repaired wheel parts.

• Make sure that all parts of the wheel are the correct parts for that wheel assembly. Make sure the rim is the correct size for the tire. Lubricate the part of the wheel that contacts the bead and flap.

• Do NOT mix parts between different types or manufacturers of wheels.

• Do NOT mix types of tires, type of tire tread, or wheel assemblies of different manufacturers on any one lift truck.

• Do NOT use a steel hammer on the wheel. Use a rubber, lead, plastic, or brass hammer to put parts together. Make sure that the side ring is in the correct position. The ends of the side ring must not touch. The clearance at the ends of the lock ring will be approximately 13 to 25 mm (0.5 to 1.0 in.) after it is installed. If the clearance is wrong, the wrong part has been used.

• Apply a rubber lubricant or a soap solution to the tire bead and tube.

Do not lubricate the tire bead with antifreeze or petroleum-based liquid. Vapors from these liquids can cause an explosion during inflation or use.

STEP 1.

Install the inner tube and the rubber flap in the tire.

STEP 2.

Install the wheel rim in the tire. Make sure the stem of the inner tube is aligned with the slot in the rim.

41

Wheels and Tires Maintenance

8000 SRM 772

STEP 3.

Turn over the rim and tire. Put blocks under the rim so the rim is 8 to 10 cm (3 to 4 in.) above the floor.

Install the flange seat (if used) and the side flange.

Hold them in the correct position.

STEP 4.

Put the lock ring in the correct position on the rim.

Add air pressure to the tire as described in Add Air to Tires.

Add Air to Tires 1. Put the tire in the safety cage.

2. Add 20 kPa (3 psi) of air pressure to the tire. See Figure 29.

4. If installation is not correct, remove all of the air pressure from the tire. Remove the valve core to make sure all of the air pressure has been removed and then make adjustments. The clearance at the ends of the lock ring will be approximately 13 to 25 mm (0.5 to 1.0 in.) when the tire has the correct air pressure.

5. If installation is correct, add the specified air pressure to the tire.

PNEUMATIC-SHAPED SOLID TIRES Remove Wheel From Lift Truck WARNING Wheels must be changed and tires repaired by trained personnel only. Always wear safety glasses.

Figure 29. Add Air to Tires 3. Check that all wheel parts are correctly installed.

Tap the lock ring lightly to make sure that it is in the seat.

42

1. Loosen the wheel lug nuts. Put the lift truck on blocks. See the WARNING about How to Put Lift Truck on Blocks at the beginning of this section.

8000 SRM 772

WARNING The lifting and carrying of pneumatic-shaped solid tires is not recommended because their weight could be in excess of 45 kg (100 lb).

Where applicable use a wheel or tire dolly to

Wheels and Tires Maintenance assist in the removal and installation of the wheel.

2. Remove the wheel lug nuts, and remove the wheel and tire from the lift truck. Lift truck tires and wheels are heavy.

Press Tire From Wheel STEP 1.

Put the wheel rim on the bed of the press. Put the cage in position on the tire. Use the press to push the tire away from the side ring.

STEP 2.

Put the tire tool into the slot between the side ring and/or lock ring and the wheel rim. Remove the side ring, lock ring, and wedge band.

STEP 3.

Turn the tire over. Put a support under the wheel rim. Make sure the wheel rim is at least 150 to 200 mm (6 to 8 in.) from the bed of the press.

43

Wheels and Tires Maintenance

8000 SRM 772

STEP 4.

Put the cage in position on the tire. Use the press to push the tire from the wheel rim.

Install Tire on Wheel Keep tire tools in firm contact with the wheel parts. If the tool slips, it can move with enough force to cause an injury.

WARNING Do not lubricate the tire bead with antifreeze or petroleum-based liquid. Vapors from these liquids can cause an explosion during inflation or use.

CAUTION Too much lubricant can cause the tire to slide and move around the wheel rim.

• Clean and inspect all parts of the wheel before installing the tire. Paint any parts that have rust or corrosion.

• Do NOT use damaged or repaired wheel parts.

• Make sure that all parts of the wheel are the correct parts for that wheel assembly. Make sure the rim is the correct size for the tire. Lubricate the part of the wheel that contacts the bead and flap.

• Do NOT mix parts between different types or manufacturers of wheels.

• Do NOT mix types of tires, type of tire tread, or wheel assemblies of different manufacturers on any one lift truck.

• Do NOT use a steel hammer on the wheel. Use a rubber, lead, plastic, or brass hammer to put parts together. Make sure that the side ring is in the correct position. The ends of the side ring must not touch. The clearance at the ends of the lock ring will be approximately 13 to 25 mm (0.5 to 1.0 in.) after it is installed. If the clearance is wrong, the wrong part has been used.

• Apply a rubber lubricant or a soap solution to the tire bead and tube.

44

8000 SRM 772

Wheels and Tires Maintenance

STEP 1.

Lubricate the wheel rim and the inner surface of the tire with tire lubricant or soap.

STEP 2.

Put the wheel rim on the bed of the press. Put the tire over the wheel rim. Put the cage in position on the tire. Use the press to install the tire on the wheel rim.

STEP 3.

Remove the cage and put the wedge band (if used), the side ring, and the lock ring in position on the wheel assembly. Install the cage on the tire. Use the press to push the tire onto the wheel rim so the wedge band and side ring can be installed.

STEP 4.

While the cage is holding the tire on the wheel rim, install the lock ring. Use a tire tool to make sure the lock ring is in the correct position.

45

Wheels and Tires Maintenance

INSTALL WHEEL AND TIRE WARNING The lifting and carrying of cushion tires is not recommended because their weight could be in excess of 45 kg (100 lb). Where applicable, use a wheel or tire dolly to assist in the removal and installation of the wheel.

1. Install the tire and wheel on the hub. Tighten the lug nuts so they are snug.

2. Raise the lift truck high enough to remove the blocks. Lower the lift truck to the floor.

46

8000 SRM 772

CAUTION Check all wheel nuts after 2 to 5 hours of operation: when new lift trucks begin operation and on all lift trucks when the wheels have been removed and installed. Tighten the nuts in a cross pattern to the correct torque value shown in the Torque Chart. When the nuts stay tight for 8 hours, the interval for checking the torque can be extended to 350 hours.

3. Tighten the nuts in a cross pattern to the torque value shown in the Maintenance Schedule.

TECHNICAL PUBLICATIONS 8000 SRM 772

8/03 (7/01)(10/99) Printed in U.S.A.

DIAGRAMS J30-40XMT2 [H160]

PART NO. 1468301

8000 SRM 771

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR • When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks.

• Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit 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!

Diagrams

Table of Contents

TABLE OF CONTENTS J30-40XMT 2 (Prior to 8/01) ...............................................................................................................................

Figure 1. Wiring Schematic-Traction Control .........................................................................................

Figure 2. Wiring Schematic-Transistor Lift Pump Control ....................................................................

Figure 3. Wiring Schematic-1-Speed Lift Pump Control ........................................................................

Figure 4. Wiring Schematic-2-Speed Lift Pump Control (Not Available on all Models) .......................

Figure 5. Wiring Diagram-Seat Brake (Optional)...................................................................................

Figure 6. Wiring Diagram-Front Compartment......................................................................................

Figure 7. Wiring Diagram-Rear Compartment With Transistor Lift Pump Control ............................

Figure 8. Wiring Diagram-Rear Compartment With One-Speed Lift Pump Control ...........................

Figure 9. Wiring Diagram-Rear Compartment With Two-Speed Lift Pump Control (Not Available on all Models) ............................................................................................................................

Figure 10. Wiring Diagram-EE Option....................................................................................................

J30-40XMT 2 (After 8/01) ...................................................................................................................................

Figure 11. Wiring Schematic-Traction Control .......................................................................................

Figure 12. Wiring Schematic-Transistor Lift Pump Control ..................................................................

Figure 13. Wiring Schematic-1-Speed Lift Pump Control ......................................................................

Figure 14. Wiring Schematic-2-Speed Lift Pump Control (Not Available on all Models) .....................

Figure 15. Wiring Schematic-Seat Brake (Optional) ..............................................................................

Figure 16. Wiring Diagram-Front Compartment....................................................................................

Figure 17. Wiring Diagram-Rear Compartment With Transistor Lift Pump Control ..........................

Figure 18. Wiring Diagram-Rear Compartment With One-Speed Lift Pump Control .........................

Figure 19. Wiring Diagram-Rear Compartment With Two-Speed Lift Pump Control (Not Available On All Models) ..........................................................................................................................

Figure 20. Wiring Diagram-Rear Compartment With EE Connections ................................................

J30-40XMT 2 (Options) .......................................................................................................................................

Figure 21. Wiring Schematics ..................................................................................................................

Figure 22. Wiring Diagram (Rear Compartment)...................................................................................

Figure 23. Wiring Diagram (Front Compartment) .................................................................................

J30-40XMT 2 (Prior to 8/03) ...............................................................................................................................

Figure 24. Hydraulic Schematic (3 Function) .........................................................................................

Figure 25. Hydraulic Schematic (4 Function) .........................................................................................

J30-40XMT 2 (After 8/03) ...................................................................................................................................

Figure 26. Hydraulic Schematic (4 Function) .........................................................................................

1 1 2 3 4 5 6 7 8 9 10 11 11 12 13 14 15 16 17 18 19 20 21 21 22 23 24 24 25 26 26

This section is for the following models: J30-40XMT2 [H160]

©2003 HYSTER COMPANY

i

"THE QUALITY KEEPERS" HYSTER APPROVED PARTS

8000 SRM 771

J30-40XMT 2 (Prior to 8/01)

Figure 1. Wiring Schematic-Traction Control

1

J30-40XMT 2 (Prior to 8/01)

Figure 2. Wiring Schematic-Transistor Lift Pump Control

2

8000 SRM 771

8000 SRM 771

J30-40XMT 2 (Prior to 8/01)

Figure 3. Wiring Schematic-1-Speed Lift Pump Control

3

J30-40XMT 2 (Prior to 8/01)

8000 SRM 771

Figure 4. Wiring Schematic-2-Speed Lift Pump Control (Not Available on all Models)

4

8000 SRM 771

J30-40XMT 2 (Prior to 8/01)

Figure 5. Wiring Diagram-Seat Brake (Optional)

5

J30-40XMT 2 (Prior to 8/01)

8000 SRM 771

Figure 6. Wiring Diagram-Front Compartment

6

8000 SRM 771

J30-40XMT 2 (Prior to 8/01)

Figure 7. Wiring Diagram-Rear Compartment With Transistor Lift Pump Control

7

J30-40XMT 2 (Prior to 8/01)

8000 SRM 771

Figure 8. Wiring Diagram-Rear Compartment With One-Speed Lift Pump Control

8

8000 SRM 771

J30-40XMT 2 (Prior to 8/01)

Figure 9. Wiring Diagram-Rear Compartment With Two-Speed Lift Pump Control (Not Available on all Models)

9

J30-40XMT 2 (Prior to 8/01)

8000 SRM 771

Figure 10. Wiring Diagram-EE Option

10

8000 SRM 771

J30-40XMT 2 (After 8/01)

Figure 11. Wiring Schematic-Traction Control

11

J30-40XMT 2 (After 8/01)

Figure 12. Wiring Schematic-Transistor Lift Pump Control

12

8000 SRM 771

8000 SRM 771

J30-40XMT 2 (After 8/01)

Figure 13. Wiring Schematic-1-Speed Lift Pump Control

13

J30-40XMT 2 (After 8/01)

8000 SRM 771

Figure 14. Wiring Schematic-2-Speed Lift Pump Control (Not Available on all Models)

14

8000 SRM 771

J30-40XMT 2 (After 8/01)

Figure 15. Wiring Schematic-Seat Brake (Optional)

15

J30-40XMT 2 (After 8/01)

8000 SRM 771

Figure 16. Wiring Diagram-Front Compartment

16

8000 SRM 771

J30-40XMT 2 (After 8/01)

Figure 17. Wiring Diagram-Rear Compartment With Transistor Lift Pump Control

17

J30-40XMT 2 (After 8/01)

8000 SRM 771

Figure 18. Wiring Diagram-Rear Compartment With One-Speed Lift Pump Control

18

8000 SRM 771

J30-40XMT 2 (After 8/01)

Figure 19. Wiring Diagram-Rear Compartment With Two-Speed Lift Pump Control (Not Available On All Models)

19

J30-40XMT 2 (After 8/01)

Figure 20. Wiring Diagram-Rear Compartment With EE Connections

20

8000 SRM 771

8000 SRM 771

J30-40XMT 2 (Options)

Figure 21. Wiring Schematics

21

J30-40XMT 2 (Options)

8000 SRM 771

Figure 22. Wiring Diagram (Rear Compartment)

22

8000 SRM 771

J30-40XMT 2 (Options)

Figure 23. Wiring Diagram (Front Compartment)

23

J30-40XMT 2 (Prior to 8/03)

8000 SRM 771

Figure 24. Hydraulic Schematic (3 Function)

24

8000 SRM 771

J30-40XMT 2 (Prior to 8/03)

Figure 25. Hydraulic Schematic (4 Function)

25

J30-40XMT 2 (After 8/03)

8000 SRM 771

Figure 26. Hydraulic Schematic (4 Function)

26

TECHNICAL PUBLICATIONS 8000 SRM 771

8/03 (7/01)(8/99) Printed in U.S.A.