Hyster-J160-J1.60-2.00XMT-Service-Manual-1

FRAME
J1.6-2.0XMT (J30-40ZT) [J160]
PART NO. 1554626 100 SRM 1073

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 Mainte-
nance 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!
Frame Table of Contents
TABLE OF CONTENTS
Introduction........................................................................................................................................................ 1
General ........................................................................................................................................................... 1
Description of Operation ............................................................................................................................... 1
Discharging the Capacitors........................................................................................................................... 2
Covers and Floor Plates..................................................................................................................................... 3
Overhead Guard Repair .................................................................................................................................... 5
Remove ........................................................................................................................................................... 5
Install ............................................................................................................................................................. 5
Hood and Seat Assembly ................................................................................................................................... 6
Remove ........................................................................................................................................................... 7
Install ............................................................................................................................................................. 7
Counterweight.................................................................................................................................................... 8
Remove ........................................................................................................................................................... 8
Install ............................................................................................................................................................. 9
Safety Labels ...................................................................................................................................................... 10
Painting Instructions......................................................................................................................................... 13
This section is for the following models:
J1.6-2.0XMT (J30-40ZT) [J160]
©2004 HYSTER COMPANY i

"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
100 SRM 1073 Introduction
Introduction
GENERAL DESCRIPTION OF OPERATION
This section contains a description and the service The frame is a single weldment with mounts for the
procedures for the parts of the frame. These parts in- counterweight, overhead guard, mast, steering sys-
clude the frame, counterweight assembly, overhead tem, hydraulic system and transaxles. See Figure 2.
guard, hood and seat assembly, access panels, and The battery cover opens on hinges to give access to
labels. Throughout this section, forward will refer to the battery compartment. The weight of the battery
travel in the direction of the forks and left and right is a major part of the counterweight system on an
will be determined by an operator sitting in the seat electric lift truck. A slot in the overhead guard per-
facing forward. See Figure 1. mits removal of the battery without removing the
overhead guard. Spacers may be added under the
battery as required on some models.
Each model of lift truck has a cast-iron counter-

weight with a weight necessary for the indicated
capacity. An access panel on the top/rear of the coun-
terweight gives access to the electronic controllers.
The hydraulic pump and motor, steering pump and

motor, drive motors and transaxles, and hydraulic
tank are under the floor plates in the operator com-
partment. The floor plates are held in position by
tabs and can be removed to give access to components
underneath.
The hydraulic control valve is fastened to the front

of the battery compartment. Three covers protect the
A. LEFT SIDE
B. RIGHT SIDE control valve and control linkage. The covers are fas-
C. FORWARD TRAVEL tened in position by machine screws. The top covers
are locked in place and must be released and swung
Figure 1. Truck Orientation open before attempting to open the battery cover.
Figure 2. Frame
1
Introduction 100 SRM 1073
DISCHARGING THE CAPACITORS

CAUTION
WARNING To avoid controller damage, always disconnect
the battery, discharge the capacitor(s), and
Do not make repairs or adjustments unless you
never put power to the controller while any
have both authorization and training. Repairs
power wires are disconnected. Never short
and adjustments that are not correct can cre-
any controller terminal or motor terminal to
ate dangerous operating conditions. Do not op-
the battery. Make sure to use proper proce-
erate a lift truck that needs repairs. Report
dure when servicing the controller.
the need for repairs to your supervisor imme-
diately. If repair is necessary, attach a DO NOT 1. Turn key switch to OFF position and disconnect
OPERATE tag on the steering wheel. Remove the battery. Block load wheels to prevent lift
the key from the key switch. truck from moving.
2. Open the electrical compartment at the rear of

WARNING
the truck.
Disconnect the battery before opening the
drive unit compartment cover or inspecting or a. Remove the two screws securing the electri-
repairing the electrical system. If a tool causes cal compartment door closed.
a short circuit, the high current flow from the
battery can cause personal injury or property b. Tilt the door back on its hinges to open the
damage. compartment.
WARNING WARNING
Some checks and adjustments are done with DO NOT short across the motor controller ter-
the battery connected. Do not connect the minals with a screwdriver or jumper wire.
battery until the procedure tells you to do so.
Never have any metal on your fingers, arms, NOTE: Some lift trucks are equipped with a premium
or neck. Metal items can accidentally make an controller, which controls the hydraulic motor as well
electrical connection and cause injury. as the traction motors.
3. Discharge the capacitor in the controller by con-

WARNING necting a 200-ohm, 2-watt resistor across the
Before performing any tests or adjustments, controller’s BT+ and B terminals for 10 seconds
block the lift truck to prevent unexpected using insulated jumper wires. See Figure 3.
movement.
4. On the premium controller, also connect the 200-
ohm, 2-watt resistor across the controller’s P+
WARNING and B terminals for 10 seconds using insulated
The capacitor in the transistor controller(s) jumper wires. See Figure 4.
can hold an electrical charge after the battery
is disconnected. To prevent an electrical shock 5. Remove the 200-ohm, 2-watt resistor before re-
and personal injury, discharge the capacitor(s) connecting the battery.
before inspecting or repairing any component
in the drive unit compartment. Wear safety
glasses. Make certain that the battery has
been disconnected.
2
100 SRM 1073 Covers and Floor Plates
1. POSITIVE CONNECTION (BT+) 1. POSITIVE CONNECTION (BT+)

2. NEGATIVE CONNECTION (B ) 2. NEGATIVE CONNECTION (B )
3. INSULATED JUMPER WIRES 3. INSULATED JUMPER WIRES
4. 200-OHM, 2-WATT RESISTOR 4. 200-OHM, 2-WATT RESISTOR
5. POSITIVE CONNECTION (P+)
Figure 3. Discharging the Capacitors
(Standard) Figure 4. Discharging the Capacitors
(Premium)
Covers and Floor Plates

Many system components, such as hydraulic hoses, to these components during service and securely
pump and motor, and wiring harnesses, are located cover these areas during normal operation. See
in the area around and under the operator compart- Figure 5.
ment. Various covers and floor plates provide access
3
Covers and Floor Plates 100 SRM 1073
1. CAPSCREW 7. ANTI-SLIP PAD

2. ATTACHING HARDWARE 8. ANTI-SLIP PAD
3. CLIP NUT 9. RIGHT FLOOR PLATE
4. HARNESS COVER (ELECTRIC VALVE) 10. CENTER FLOOR PLATE
5. HARNESS COVER (MANUAL VALVE) 11. LEFT FLOOR PLATE
6. CAPSCREW 12. HOSE COVER
Figure 5. Covers and Floor Plates
4
100 SRM 1073 Overhead Guard Repair
Overhead Guard Repair

Legend for Figure 6
WARNING
The overhead guard is part of the operator pro- 1. OVERHEAD GUARD
2. COUNTERWEIGHT
tection system. Do not operate the lift truck
3. FRAME
without the overhead guard correctly fastened 4. CAPSCREWS (4) FRONT
to the lift truck. 5. CAPSCREWS (2) REAR
6. CAPSCREWS (2) UPPER
The overhead guard is designed to provide protection 7. CAPSCREWS (2) LOWER
to the operator from falling objects and in the event
of a tip over. A high visibility design allows for an 2. Use an overhead lifting device and sling to lift
unobstructed view while maintaining structural in- the overhead guard until it is just higher than
tegrity. Removal of the battery is simplified by the the counterweight mounts.
slot in the overhead guard. This provides access to
NOTE: Tie a cord around the wires from each post
the battery with an overhead lifting device without
of the overhead guard before removal. Remove the
removing the overhead guard.
wires from the post. Untie the cord from the wires
and tape each end of the cord to the overhead guard
REMOVE
where it enters the post. Use the cord to pull the
wires up through the post when installing the over-
WARNING head guard.
The overhead guard is heavy. Make sure the
sling, chain, eyebolts, and crane or lifting 3. Tag and disconnect the wiring from each post of
device have the capacity to lift the overhead the overhead guard. Carefully remove the wiring
guard. if necessary.
1. Remove the six capscrews, washers, and nuts 4. Completely remove the overhead guard from the
that secure the supports of the overhead guard lift truck.
to the counterweight and cowl. See Figure 6.
INSTALL
1. Position overhead guard just above mounts on
the counterweight and cowl using an overhead
lifting device and sling.
2. Route the wires through each overhead guard

post and install to lights as removed.
3. Lower overhead guard supports onto the mounts.
4. Install and tighten six capscrews, washers, and

nuts securing overhead guard to the lift truck.
Tighten capscrews to 134 N•m (99 lbf ft).
5. Remove sling and overhead guard.
Figure 6. Overhead Guard Mounting
5
Hood and Seat Assembly 100 SRM 1073
Hood and Seat Assembly

The hood is the platform for the seat assembly and A large, red button switch is mounted on the hood at
is located above the battery. It functions as a battery the right side of the seat assembly. This switch is an
restraint that completely covers the battery compart- emergency battery disconnect that allows the opera-
ment. See Figure 7. Its function as the battery re- tor to quickly disconnect the battery while seated on
straint, when correctly locked to the frame, is to hold the lift truck in case of an emergency.
the battery in the battery compartment if an accident
causes the lift truck to tip over. The hood is com- The seat assembly slides on seat rails that are fas-
posed of a plastic cover attached to a metal frame. tened to the hood by four capscrews. A lever at the
Two hinges at the back of the hood attach it to the left front side of the base controls the adjustment of
frame. A sliding latch mechanism on the front of the the seat to the forward and backward positions. Op-
hood locks the hood closed during operation. A dou- tional seats are available in cloth or vinyl with fea-
ble-dampened, gas-controlled strut holds the hood in tures such as semi-suspension, full suspension, and
the open position. limited swivel. All seats have a seat switch installed
in the bottom cushion that senses operator presence.
Opening the sliding latch unlocks the hood from the When the operator is not on the seat, the seat switch
frame so the hood can be raised to access the bat- opens and interrupts the controller stopping opera-
tery. See Figure 8. The latch can only be accessed tion of the lift truck.
after releasing and raising the hydraulic levers and
linkage assembly up and out of the way. A button on The hood, seat belt, hip restraint brackets, seat, and
each side of the assembly can be pressed to release seat mount are all parts of the operator restraint sys-
the assembly so it can be moved clear of the hood on tem. Checks and adjustments for the operator re-
its hinged bracket. The latch must be in good condi- straint system are described in the Operating Man-
tion and properly secured before the lift truck can be ual and the section Periodic Maintenance 8000
operated. If the latch does not lock the hood in the SRM 1079.
closed position, the hydraulic levers and linkage as-
sembly will not lock into position and the lift truck
will not operate.
1. SEAT 2. HOOD 3. SEAT SWITCH CONNECTOR
Figure 7. Hood and Seat Assembly
6
100 SRM 1073 Hood and Seat Assembly
To raise the hood and seat assembly, move the seat 4. Remove the stop screws from the seat assembly,
to the rear of the hood if necessary. Move the steer- hold the slide function lever in the open position,
ing column to the most forward position. Release and slide the seat from the mounting bracket.
and raise the hydraulic levers and linkage. Open the Remove mounting bracket from hood if neces-
latch mechanism and raise the hood. sary.
5. Disconnect the double-dampened, gas-controlled

struts by removing the locking clips retaining the
struts to the hood and the capscrews securing the
lower ends to frame. Move the hood to the closed
position.
6. Remove capscrews securing hood mounting

brackets to hood and lift hood from truck.
7. Slide hood mounting brackets from studs on

counterweight brackets. Replace bushings if
necessary.
8. Remove the capscrews, washers, and nuts retain-

ing the hood cover to its metal frame if necessary.
INSTALL
1. Install the capscrews, washers, and nuts to se-
cure the hood cover to its metal frame.
2. Install new bushings to mounting brackets if nec-

essary. Slide hood mounting brackets onto coun-
1. SLIDING LATCH MECHANISM terweight bracket studs as removed.
2. HOOD
3. FRAME 3. With the aid of an assistant or overhead lifting
device and sling, position the hood on the hinges
Figure 8. Latch Mechanism and install the four capscrews. Tighten snugly
but do not torque at this time. Place the hood in
REMOVE the closed position.
1. Disconnect the battery connector. 4. Open and close the hood to check for proper
2. Tag and disconnect the electrical connectors clearance. The minimum clearance between the
to the emergency battery disconnect, the seat hood and the front plate of the frame is 3.5 mm
switch, and the hood and latch position switches. (0.14 in.). Check to ensure the proper clearance.
Remove hood and latch switches if necessary. 5. Tighten the capscrews to 86 N•m (63 lbf ft).
3. Remove the emergency battery disconnect switch 6. Raise the hood. Align and install the gas-filled
and hood and latch position switches, if neces- struts and install the locking clips to retain the
sary. struts to the hood and install capscrews to secure
NOTE: The seat assembly does not have to be re- the lower ends to frame.
moved from the hood to remove the hood from the 7. If the seat assembly has been removed, in-
lift truck. To remove the seat, remove the four cap- stall the mounting bracket to the hood using
screws that fasten the seat base to the hood. Lift the capscrews, washers, and nuts. Hold the slide
seat assembly from the hood. If the seat is not being function lever in the open position and slide the
removed, raise the hood.
7
Counterweight 100 SRM 1073
seat into mounting bracket tracks. Release the 9. Connect the wiring harnesses to the seat switch,
lever and install the stop screws. emergency battery disconnect, and the hood and
latch position switches.
8. Install hood and latch switches and emergency
battery disconnect switch, if removed, and adjust 10. Close the hood. Make certain that the locking
as necessary. mechanism to retain the hood is properly en-
gaged. Close the hydraulic linkage and covers.
11. Connect the battery connector.
Counterweight
WARNING
Do not operate the lift truck if the capscrews
for the counterweight are not installed. When
the capscrews are removed, the counterweight
can fall from the lift truck.
A one-piece, cast iron counterweight is used to off-

set the weight of the load. See Figure 9. The coun-
terweight is mounted to the rear of the truck using
four mounting bolts and is supported by a protruding
flange of the frame. See Figure 9. A compartment
space, accessed by a hinged door, has been designed
into the center of the counterweight to house the elec-
trical connections.
A battery platform is used to support the battery on

the lift truck frame. The battery platform also serves
as part of the counterweight system and requires the
use of an overhead lifting device for removal or in-
stallation. Be sure to replace the same battery plat-
form, or one of equal weight, if the platform must be
removed.
REMOVE
1. Remove battery. See the section Periodic Main-
tenance 8000 SRM 1079 for instructions on re-
moving the battery.
NOTE: It may not be necessary to remove the battery

platform. Perform only the steps necessary to com- Figure 9. Counterweight
plete the required service.
3. Remove overhead guard. See Overhead Guard
2. Remove battery platform if necessary: Repair.
a. Remove the battery spacer and the acid tray 4. Remove the two large screws securing the elec-
positioned on top of the battery platform. trical compartment access door in the closed po-
sition and pull open the door.
b. Remove the two capscrews, washers, and
nuts retaining the platform to the frame. 5. Discharge the capacitor(s). See Discharging the
Capacitors.
c. Use a lifting device to lift the platform out of
the lift truck.
8
100 SRM 1073 Counterweight
NOTE: Make note of wires and cable routing for 2. Install the four capscrews and hardened flat
proper reassembly. washers that hold the counterweight to the
frame. Tighten the capscrews to 435 N•m
6. Remove socket head screws and detach the con- (321 lbf ft).
troller panel from the electrical compartment ac-
cess door. Remove wire ties securing wires and 3. Disconnect the chain. Remove the clevis from
cables to the door hinge mechanism. each overhead guard mount.
7. Remove the electrical compartment access door 4. If removed, install the electrical compartment
and hinges if necessary. hinges and door.
5. Install the controller panel to the inside of the

WARNING electrical compartment door using the proper
The counterweight is very heavy. Make sure socket head screws. Secure wires and cables
the chains, eyebolts, and overhead lifting inside the electrical compartment as removed.
device have the capacity to lift the counter-
weight.
8. Install a clevis on each of the overhead guard

mounts. See Figure 10. Install tempered, grade
8 bolts and nuts or the proper pins for each cle-
vis. Attach a chain to each clevis. Use an over-
head lifting device to hold the weight of the coun-
terweight. Make sure the sling, chain, eyebolts,
and overhead lifting device have the capacity to
lift the counterweight.
9. Remove the four M20 × 2.5 × 60 capscrews and

hardened flat washers that hold the counter-
weight to the frame. Four capscrews hold the
counterweight to the frame from the inside and
can be accessed from the battery compartment.
Two of the capscrews are located at the bottom
of the counterweight, while the other two are
located approximately in the center of the coun-
terweight. The nuts for the capscrews are cast
in the counterweight. Refer to Figure 6.
10. Use the overhead lifting device to lift the coun-

terweight off the mounting flange and away from
the frame. See Figure 9.
INSTALL
WARNING
The counterweight is very heavy. Make sure
the chains, eyebolts, and overhead lifting
device have the capacity to lift the counter-
weight.
1. CHAIN
1. Use an overhead lifting device to lift the counter- 2. OVERHEAD GUARD MOUNTS
weight into position. See Remove, Step 8. Some 3. CLEVIS
assistance will be required to align the mount-
ing holes in the counterweight with those in the Figure 10. Lifting the Counterweight
frame.
9
Safety Labels 100 SRM 1073
6. Close the door to the electrical compartment and c. Install the battery spacer and the acid tray
secure using two large screws. on top of the battery platform.
7. Install the battery platform and the acid tray in 8. Install the overhead guard. See Overhead Guard
the battery compartment. Repair.
a. Use an overhead lifting device to place the 9. Install the battery. See the section Periodic
platform into the lift truck. Maintenance 8000 SRM 1079.
b. Install the two capscrews, washers, and nuts

retaining the platform to the frame.
Safety Labels
1. Clean the painted surface. Use household clean-
WARNING ing products to clean new paint and clean old
Safety labels are installed on the lift truck to paint with cleaning solvent. DO NOT use sol-
give information about operation and possible vent on new paint. Make sure the surface is dry
hazards. It is important that all safety labels and is clean of dirt, oil, and grease.
are installed on the lift truck and can be read.
2. Remove the paper from the back of the label and
DO NOT add to or modify the lift truck. Any hold the label by the edges. Do not touch the
change to the lift truck, the tires, or its equip- adhesive surface.
ment can change the lifting capacity. The lift
truck must be rated as equipped and the name-
plate must show the new capacity rating. Con-
CAUTION
tact your Hyster lift truck dealer for a replace- The label cannot be moved after it touches the
ment nameplate. surface.
If a label must be replaced, use the following proce- 3. Carefully hold the label in the correct position
dure to install a new label. See Figure 11, Figure 12, above the surface and carefully apply to the cor-
and Figure 13. rect location. Make sure that all air is removed
from under the label by smoothing any wrinkles
or bubbles with your fingers working from the
WARNING center out. Check that the corners and edges are
Always use solvents and paints in an area with tight against the surface.
adequate ventilation. Do not use solvents or
paints near heat, fire, or electrical equipment
that can create sparks. Follow the manufac-
turer’s instructions and cautions.
10
100 SRM 1073 Safety Labels
A. SIDE VIEW B. REAR VIEW C. FRONT VIEW

1. OVERHEAD GUARD IMPACT RATING PLATE 11. EE CONSTRUCTION
2. MAST WARNING 12. BATTERY SPACER WARNING
3. HYSTER 13. HYSTER
4. OPERATOR RESTRAINT 14. PATENTS AND TRADEMARKS
5. TILT COLUMN 15. UL LABEL
6. MAST WARNING 16. AUXILIARY FUNCTION
7. PINCH POINT 17. SIDESHIFT
8. UNIT NUMBER DECAL 18. TILT
9. HYSTER 19. LIFT
10. CORROSION/FREEZER 20. LABEL (EUROPEAN ONLY)
Figure 11. Label Locations - General
11
Safety Labels 100 SRM 1073
1. LOCK/UNLOCK
2. NAMEPLATE
3. PINCH POINT
4. PINCH POINT
5. OPERATOR WARNING
6. BATTERY DISCONNECT
1. BRAKE SYSTEM FLUID LABEL 7. PINCH POINT
2. HYDRAULIC OIL FILL LABEL 8. NO RIDERS
3. BRAKE SYSTEM FLUID TAG 9. PINCH POINT
Figure 12. Label Locations - Below Floor Plates Figure 13. Label Locations - Battery
Compartment Cover
12
100 SRM 1073 Painting Instructions
Painting Instructions
Labels and Information Plates
WARNING Seat Assembly and Rails
Always use solvents and paints in an area Information Case
with ventilation. Do not use solvents or paints Tires
near heat, fire, or electrical equipment that Mast Chains and Hoses
can make sparks. Follow the manufacturer’s Battery Connector
instructions and cautions. Key Switch
Cylinder Rods
1. Remove all dirt from the surface to be painted. All Plastic Covers
Clean the area to be painted. Use a solvent for
painted surfaces to remove grease and oil before
sanding. Do not use solvent on new paint. Make CAUTION
sure all oil and grease is removed. Do not paint the pads, plastic covers or knobs,
cables, labels, information plates, or controls.
2. Use sandpaper to remove the top surface of Paint can make some assemblies not operate
paint and rust from the metal. All metal sur- correctly.
faces where the paint is completely removed,
must be primed. Apply primer before applying 4. Paint the surfaces. Use the correct paint from
the paint. your dealer for Hyster lift trucks. Follow the di-
rections on the container.
CAUTION
DO NOT put tape on cylinder rods to protect
WARNING
from paint. Use a thick layer of multipurpose Make sure all labels are installed after paint-
grease to protect cylinder rods. Cylinders can ing is complete. Safety labels are installed on
be damaged if operated with tape on the cylin- the lift truck to give information about possi-
der rod. ble hazards. It is important that all safety la-
bels are installed on the lift truck and can be
3. Protect all surfaces that will not be painted. read.
DO NOT paint:
Pedal Pads 5. Check that all labels are installed in the correct
Lever Knobs locations on the lift truck. See Safety Labels.
Instrument Panel
NOTE: Use colors approved by Hyster Company.
Steering Wheel
13
NOTES
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
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____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
14
TECHNICAL PUBLICATIONS
100 SRM 1073 6/04 Printed in United Kingdom

AC TRACTION MOTOR
REPAIR
J1.6-2.0XMT (J30-40ZT) [J160]
PART NO. 1566043 620 SRM 1115

SAFETY PRECAUTIONS

trucks.
nance section.
manual:
WARNING
CAUTION
AC Traction Motor Repair Table of Contents
TABLE OF CONTENTS
Introduction........................................................................................................................................................ 1
General ........................................................................................................................................................... 1
Description ......................................................................................................................................................... 3
Traction Motor ............................................................................................................................................... 3
AC Motor Repair ................................................................................................................................................ 4
Remove ........................................................................................................................................................... 4
Disassemble ................................................................................................................................................... 4
Inspect ............................................................................................................................................................ 4
Assemble ........................................................................................................................................................ 4
Install ............................................................................................................................................................. 6
Troubleshooting.................................................................................................................................................. 6
J1.6-2.0XMT (J30-40ZT) [J160]

"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
Introduction
GENERAL Troubleshooting information about the traction mo-
tors is available through on-board diagnostics and
This section contains repair and maintenance proce- may be displayed on the dash display. Refer to the
dures for the AC traction motor. Additional infor- section AC Motor Controllers/Display Panel,
mation concerning the traction motor may be more Description, Checks, Adjustments, and Trou-
closely related to other systems and included in those bleshooting 2200 SRM 1087 for further explanation
sections. Sections that contain information regard- of dash display codes concerning the traction motors.
ing the traction motors include:
AC Motor Controllers/Display Panel, De- DISCHARGING THE CAPACITORS
scription, Checks, Adjustments, and Trou-
bleshooting 2200 SRM 1087
WARNING
Electrical System 2200 SRM 1078
Periodic Maintenance 8000 SRM 1079 Do not make repairs or adjustments unless you
are properly trained and have authorization to
do so. Repairs and adjustments that are not
WARNING correct can create dangerous operating condi-
Do not make repairs or adjustments unless you tions. Do not operate a lift truck that needs re-
are properly trained and have authorization to pairs. Report the need for repairs to your su-
do so. Repairs and adjustments that are not pervisor immediately. If repair is necessary, at-
correct can create dangerous operating condi- tach a DO NOT OPERATE tag to the steering
tions. Do not operate a lift truck that needs re- wheel and remove the key.
pairs. Report the need for repairs to your su-
pervisor immediately. If repair is necessary, at-
tach a DO NOT OPERATE tag to the steering WARNING
wheel and remove the key. Disconnect the battery before opening the elec-
trical compartment cover or inspecting or re-
Throughout this section, forward will refer to travel pairing the electrical system. If a tool causes
in the direction of the forks and left and right will be a short circuit, the high current flow from the
determined by sitting in the seat facing forward. See battery can cause personal injury or property
Figure 1. damage.
WARNING
Some checks and adjustments are performed
with the battery connected. Do not connect the
Never have any metal on your fingers, arms,
or neck. Metal items can accidentally make an
electrical connection and cause injury.
WARNING
Block the lift truck drive tires to prevent unex-
pected movement before performing any tests
or adjustments.
A. LEFT SIDE
B. RIGHT SIDE
C. FORWARD TRAVEL
Figure 1. Truck Orientation
1
WARNING
The capacitor in the transistor controller can
hold an electrical charge after the battery is
disconnected. To prevent an electrical shock
and personal injury, discharge the capacitor
in the electrical compartment. Wear safety
been disconnected.
CAUTION
To avoid controller damage, always discon-
nect the battery and discharge the capacitor.
NEVER put power to the controller while any
power wires are disconnected. NEVER short
dure when servicing the controller. 1. POSITIVE CONNECTION (BT+)
2. NEGATIVE CONNECTION (B )
1. Block load wheels to prevent lift truck from mov- 3. INSULATED JUMPER WIRES
ing. 4. 200-OHM, 2-WATT RESISTOR
2. Turn key switch to OFF position and disconnect Figure 2. Discharging the Capacitors
the battery. (Standard)
3. Open the electrical compartment:
a. Remove two screws securing the electrical

compartment door.
b. Pull the compartment door open on its

hinges.
WARNING
DO NOT short across the motor controller ter-
minals with a screwdriver or jumper wire.

necting a 200-ohm, 2-watt resistor across the
controller’s BT+ and B terminals for 10 seconds
using insulated jumper wires. See Figure 2.
NOTE: Some lift trucks are equipped with a premium

controller, which controls the hydraulic motor as well
as the traction motors. 1. POSITIVE CONNECTION (BT+)
5. On the premium controller, also connect the 200- 3. INSULATED JUMPER WIRES
ohm, 2-watt resistor across the controller’s P+ 4. 200-OHM, 2-WATT RESISTOR
and B terminals for 10 seconds using insulated 5. POSITIVE CONNECTION (P+)
jumper wires. See Figure 3.
6. Remove the 200-ohm, 2-watt resistor before re- (Premium)
connecting the battery.
2
620 SRM 1115 Description
Description
TRACTION MOTOR continuous motor speed and direction information to
the controller. A temperature sensor built into the
Traction motors are mounted to the inside of each end head continually monitors motor temperature.
transmission under the front end of the frame. See Brass terminals receive the power cables from the
Figure 4. controller and a small connector links the end head
(brake) wiring harness to the main wiring harness.
The rotor shaft extends out each side of the traction
motor. The splined end of the shaft engages the input
gear in the transaxle. A short, round section of the
shaft protrudes from the other side of the motor. This
end supports the parking brake hub using a woodruff
key and a snap ring. See Figure 5.
1. LEFT TRANSMISSION
2. TRACTION MOTORS
3. RIGHT TRANSMISSION
Figure 4. Transmission Mounting
The traction motors are three-phase AC induction

motors. DC battery current is converted into AC cur-
rent in the controller and then supplied to the trac- Figure 5. Traction Motor
tion motors. The controller controls motor speed and
direction. Each traction motor contains a speed en-
coder device in the end head (brake) that provides
3
AC Motor Repair 620 SRM 1115
AC Motor Repair
REMOVE 7. If necessary, remove the nuts and washers secur-
ing the connection plate to the stator, and remove
1. Turn the key switch to the OFF position and dis- the connection plate.
connect the battery. Block the steer tires to pre-
vent unexpected movement. INSPECT
2. Remove the mast assembly. See the section Inspect the rotor and the inside of the stator for
Mast, Description 4000 SRM 521. marks or grooves indicating contact between the
rotor and the stator. Replace if damaged. Check
3. Position the front of the lift truck on solid hard-
that the bearing rolls smoothly and is not loose from
wood blocks so the drive tires are suspended
excessive wear. Replace end head (brake) assembly
off the floor. See the section Periodic Main-
if bearing is worn/damaged. If there is damage from
tenance 8000 SRM 1079 for instructions on
contact between the rotor and the stator or to other
putting the lift truck on blocks.
components, replace damaged components or the
4. Remove the transaxle assembly from the lift complete traction motor assembly if necessary.
truck. See the section Transaxle 1300 SRM
1074. ASSEMBLE
5. Remove the four capscrews and washers mount- 1. Install end head (transaxle) into stator as re-
ing the traction motor to the transaxle. moved.
6. Remove the traction motor from the transaxle. 2. Install rotor into stator with drive splines pro-
truding through the end head (transaxle).
DISASSEMBLE 3. Install connector to end head (brake) wiring har-
1. Remove the four capscrews, lockwashers, and ness if replacing, and secure connector to end
washers securing the brake assembly to the head (brake) as removed.
drive motor. Remove the brake assembly from
4. Install connection plate to stator, if removed.
the splined hub.
5. Install end head (brake) onto rotor shaft and into
2. Remove the snap ring securing the splined hub
stator as removed.
from the traction motor shaft. Remove the
splined hub and key. 6. Install end head wiring harness into grommet
and install grommet into connector plate.
3. Remove the socket-head capscrews and lock-
washers securing motor assembly together. See NOTE: Only torque values for nonstandard applica-
Figure 6. tions are specifically stated. Refer to the section Met-
ric and Inch (SAE) Fasteners 8000 SRM 231 for
NOTE: Note: Carefully tap the underside of the end
standard torque specifications.
head with a soft hammer to loosen the end head from
the stator. 7. Install socket-head capscrews and lockwashers
through the end head (transaxle) and into the
4. Remove the end head (brake) from the stator and
end head (brake) securing motor assembly.
slide the end head off the rotor shaft.
8. Install the splined hub and key to the traction
5. Remove the rotor from the stator. Place the sta-
motor shaft. Install the snap ring securing the
tor brake end down on the workbench.
hub.
NOTE: Note: Carefully tap the underside of the end
9. Install the brake assembly onto the splined hub.
head with a soft hammer to loosen the end head from
Install the four capscrews, lockwashers, and
the stator.
washers securing the brake assembly to the
6. Remove the end head (transaxle) from the stator. drive motor as removed.
4
620 SRM 1115 AC Motor Repair
Figure 6. AC Traction Motor
5
Troubleshooting 620 SRM 1115
Legend for Figure 6

1. END HEAD (TRANSAXLE) 4. STATOR, TERMINALS, AND HARDWARE
2. ROTOR 5. CONNECTION PLATE, SCREW, AND GROMMET
3. SOCKET-HEAD CAPSCREW AND 6. END HEAD (BRAKE)
LOCKWASHER 7. CONNECTOR AND SCREW
INSTALL WARNING
1. Position the traction motor onto the transaxle as Bleed the service brakes when the transaxle
removed. has been removed. Refer to the section Peri-
odic Maintenance 8000 SRM 1079.
2. Install the four capscrews and washers mount-
ing the traction motor to the transaxle. Apply NOTE: Check the transaxle oil level and fill as needed
Loctite™ 271 and torque to 48 N•m (35 lbf ft). each time any service is performed on the transaxle
assembly.
3. Install the transaxle assembly to the lift truck.
Secure using five capscrews. Apply Loctite™ 271 5. Lower the lift truck from the blocks.
and torque to 220 N•m (162 lbf ft). See the sec-
6. Turn the key switch to the ON position and con-
tion Transaxle 1300 SRM 1074.
nect the battery. Remove the blocks from the
4. Connect all wiring and cables as removed. wheels. Test for proper operation.
Torque nuts on terminal studs to 8 N•m
7. Install the mast assembly. See the section Mast,
(71 lbf in).
Description 4000 SRM 521. Check the mast
for proper operation and return the lift truck to
service.
Troubleshooting
PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION
Truck moves slow or acceler- End head (brake) wire harness dam- Check and repair end head (brake)
ates erratically. aged. wire harness or replace end head
(brake) assembly if necessary.
Main wiring harness damaged. Test traction motor circuit through

main wiring harness from connection
at controller.
Encoder bearing damaged. Replace end head (brake) - includes

encoder bearing and temperature
sensor.
Throttle position sensor broken or Troubleshoot the accelerator assem-

out of adjustment. bly.
Parking brake not releasing. Troubleshoot the parking brakes.
6
620 SRM 1115 Troubleshooting
Temperature sensor mal- End head (brake) wire harness dam- Check and repair end head (brake)
function. aged. wire harness or replace end head
(brake) if necessary.
Main wiring harness damaged. Test temperature sensor circuit

through main wiring harness from
connection at controller.
Temperature sensor open or shorted. Measure resistance with ohmmeter.

Resistance should between 514 and
700 ohms. Replace end head (brake)
if necessary.
Traction motor does not oper- Battery lacks sufficient charge. Charge/change battery.
ate.
Throttle position sensor or neutral Troubleshoot the accelerator assem-

switch broken or out of adjustment. bly.
Electrical system malfunction. Troubleshoot the electrical system.
Operator presence switch malfunc- Check wiring/connectors. Replace

tion. switch if necessary.
Stator coil shorted to case. Check resistance between winding

and case. Resistance should be at
50,000 ohms or above. Replace sta-
tor or traction motor assembly if
necessary.
Stator wires broken-open circuit. Check resistance between motor

terminals U, V, and W. Resistance
should read less than 1 ohm between
each terminal. Replace stator or
traction motor assembly if necessary.
Parking brake not releasing/dam- Troubleshoot the parking brakes.

aged.
Transaxle internal damage. Check that the transaxle rotates

smoothly.
7
Unusual noise from traction Traction motor bearing damaged. Replace end head(s) and check stator
motor. and rotor for damage. Replace dam-
aged components or traction motor if
necessary.
Parking brake not releasing/dam- Troubleshoot the parking brakes.

aged.
Transaxle internal damage. Check that the transaxle rotates

smoothly.
8

TRANSAXLE
J1.6-2.0XMT (J30-40ZT) [J160]
PART NO. 1554627 1300 SRM 1074

SAFETY PRECAUTIONS

trucks.
nance section.
manual:
WARNING
CAUTION
Transaxle Table of Contents
TABLE OF CONTENTS
Introduction........................................................................................................................................................ 1
General ........................................................................................................................................................... 1
Description ......................................................................................................................................................... 3
Transmission.................................................................................................................................................. 3
Traction Motor ............................................................................................................................................... 3
Maintenance....................................................................................................................................................... 4
Oil Level Check.............................................................................................................................................. 4
Oil Change ..................................................................................................................................................... 4
Transaxle Assembly ........................................................................................................................................... 5
Remove ........................................................................................................................................................... 5
Disassemble ................................................................................................................................................... 6
Traction Motor and Covers ....................................................................................................................... 6
Brake Assembly and Gears....................................................................................................................... 7
Planetary Gears and Drive Axle............................................................................................................... 9
Clean and Inspect .......................................................................................................................................... 10
Assemble ........................................................................................................................................................ 11
Planetary Gears and Drive Axle............................................................................................................... 11
Brake Assembly and Gears....................................................................................................................... 12
Traction Motor and Covers ....................................................................................................................... 13
Install ............................................................................................................................................................. 15
J1.6-2.0XMT (J30-40ZT) [J160]

"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
Introduction
GENERAL Legend for Figure 1
This section contains the removal, disassembly, re- A. LEFT SIDE

pair, inspection, assembly, and installation instruc- B. RIGHT SIDE
C. FORWARD TRAVEL
tions for the transmission and traction motor that
make up the transaxle assemblies used on these mod-
els.
Some components associated with the transaxle are WARNING

not covered in this section because they are more Do not make repairs or adjustments unless you
closely associated with other systems. are properly trained and have authorization to
See the section Brake System 1800 SRM 1076 for do so. Repairs and adjustments that are not
information on the electric brake and the service correct can create dangerous operating condi-
brake lines and master cylinder. tions. Do not operate a lift truck that needs re-
See the section Periodic Maintenance 8000 pairs. Report the need for repairs to your su-
SRM 1079 for information on the tire and wheel pervisor immediately. If repair is necessary, at-
assemblies. tach a DO NOT OPERATE tag to the steering
wheel and remove the key.
WARNING
Do not make repairs or adjustments unless you WARNING
are properly trained and have authorization to Disconnect the battery before opening the
do so. Repairs and adjustments that are not electric compartment cover or inspecting or
correct can create dangerous operating condi- repairing the electrical system. If a tool causes
tions. Do not operate a truck that needs re- a short circuit, the high current flow from the
pairs. Report the need for repairs to your su- battery can cause personal injury or equip-
pervisor immediately. If repair is necessary, at- ment damage.
tach a DO NOT OPERATE tag to the steering
WARNING
Throughout this section, forward will refer to travel Some checks and adjustments are performed
in the direction of the forks and left and right will be with the battery connected. Do not connect
determined by sitting in the seat facing forward. See the battery until the procedure tells you to do
Figure 1. so. Never wear jewelry or other metal items on
your fingers, arms, or neck when performing
service to the lift truck. Metal items can ac-
cidentally make an electrical connection and
cause injury.
WARNING
or adjustments.
1
6. Remove the 200-ohm, 2-watt resistor before re-

WARNING connecting the battery.
been disconnected.
CAUTION
nect the battery and discharge the capacitor
before performing service or repairs inside
the electrical compartment. NEVER apply
power to the controller when any wires are
disconnected. NEVER short any controller
terminal or motor terminal to the battery. Al-
ways use proper procedure when servicing the
controller.
1. POSITIVE CONNECTION (BT+)
1. Block load wheels to prevent lift truck from mov- 2. NEGATIVE CONNECTION (B )
ing. 3. INSULATED JUMPER WIRES
4. 200-OHM, 2-WATT RESISTOR
2. Turn key switch to OFF position and disconnect
the battery.
(Standard)

compartment door.

hinges.
WARNING

as the traction motors.

using insulated jumper wires. See Figure 2. 1. POSITIVE CONNECTION (BT+)
(Premium)
2
Description
TRANSMISSION TRACTION MOTOR
The lift truck uses two transmissions. One transmis- The traction motor is a three-phase AC induction mo-
sion is mounted on each side of the lift truck frame tor. DC battery current is converted into AC current
beneath the cowl. The transmission is an in-line in the motor controller and then supplied to the trac-
gear set that incorporates a wet disk brake assembly tion motor. The traction controller controls motor
within the transmission housing. The traction mo- speed and direction. Each traction motor contains
tor is mounted on one side of the transmission, and a speed encoder device that provides continuous mo-
the drive wheel and tire assemblies are mounted to tor speed and direction information to the motor con-
the other side of the transmission. See Figure 4. The troller. Each traction motor also contains a tempera-
transmission is secured to the lift truck frame using ture sensor that continually monitors motor temper-
a series of five capscrews. The transmission housing ature and communicates that information to the mo-
provides the mounts needed to attach the mast to the tor controller. See Figure 5.
lift truck.
Power from the traction motor is transmitted to the

transmission through an internal spline in the input
gear. The input gear drives the first reduction gear.
The input and first reduction gear are helical gears.
The first reduction gear acts as the power input to
a three-planet, single-reduction, planetary gear set.
This planetary gear set drives the output (wheel hub)
to rotate the drive tire and move the lift truck.
Figure 5. Traction Motor
1. LEFT TRANSMISSION
2. TRACTION MOTORS
3. RIGHT TRANSMISSION
Figure 4. Transmission Mounting
3
Maintenance 1300 SRM 1074
Maintenance
OIL LEVEL CHECK 2. Turn the key switch to the OFF position and dis-
connect the battery. Block the wheels to prevent
Each transaxle has a separate oil supply which must unexpected movement.
be maintained. See Figure 6. Make sure the lift truck
is parked in a level area. To check the oil level, re- 3. Place a drip pan with at least a 3.8 liter (1 gal)
move the oil fill plug. The oil should be level with capacity under each transaxle.
the bottom of the oil fill hole. If necessary, add oil
through the oil fill hole until the oil is level with the 4. Remove the fill plugs on each transaxle. If the
bottom of the hole. Replace the oil fill plug and torque transaxle is pressurized when the fill plug is re-
to 40 N•m (30 lbf ft). Check the oil level in both moved, inspect the breather for proper operation.
transaxles every 500 hours or every three months. Clean or replace as necessary. See Figure 7.
1. BRAKE BLEED VALVE

2. TRANSAXLE HOUSING
3. DRAIN PLUG
1. OIL FILL PLUG Figure 7. Transaxle Drain Plug

2. R.H. TRANSAXLE
3. TRACTION MOTOR 5. Remove the drain plugs on each transaxle.
4. PARKING BRAKE
Figure 6. Transaxle Oil Fill Plug CAUTION

Disposal of lubricants and fluids must meet lo-
OIL CHANGE cal environmental regulations.
6. After both transaxles have drained completely,

WARNING replace the drain plugs and torque to 40 N•m
The oil is hot at normal operating tempera- (30 lbf ft). Remove the drip pans and dispose of
tures. Be careful when draining the oil. waste oil properly.
NOTE: Operate the lift truck for 5 minutes or until 7. Fill the transaxles with oil until level with the
the transaxle is warm to the touch. Oil is thick and bottom of the oil fill holes. See Figure 6.
will drain easier and more thoroughly when it is
warm. Each transaxle uses separate, self-contained 8. Install the fill plugs and torque to 40 N•m
oil supplies. The oil in the transaxle should be (30 lbf ft).
changed after the first 200 hours of operation and
every 1000 hours or every six months thereafter.
1. Raise and safety-chain the mast to access the

transaxle assemblies. See Periodic Mainte-
nance 8000 SRM 1079.
4
1300 SRM 1074 Transaxle Assembly
Transaxle Assembly
REMOVE d. Allow the oil to completely drain from the
transaxle and properly dispose of the waste
WARNING oil.
The lift truck must be put on blocks for some 9. Loosen, but do not remove, the five mounting
types of maintenance and transaxle repair. capscrews and nuts that hold the transaxle as-
The removal of the battery, mast, transaxle, sembly to the lift truck.
or the counterweight will cause large changes
in the center of gravity. Position additional 10. Disconnect the brake line from the master cylin-
blocks under the frame when the lift truck is der at the port on the transaxle. Cap the brake
on blocks, so the lift truck cannot tip over. line and plug the port on the transaxle to reduce
the possibility of contamination entering the
1. Remove the mast assembly. See Mast, Repairs brake system.
4000 SRM 522 for instructions on removing the
mast from the lift truck.
WARNING
NOTE: DO NOT remove the battery. The transaxle and traction motor assemblies
are heavy. Be sure that all lifting devices are
2. Turn the key switch to the OFF position and dis- suitable and of adequate capacity to lift the
connect the battery. transaxle and traction motor.
3. Position the front of the lift truck on blocks so 11. Position a floor jack under the transaxle assem-
the drive tires are suspended off the floor. See bly. Make sure the assembly is properly balanced
Periodic Maintenance 8000 SRM 1079 for in- on the floor jack so it will not fall once the mount-
structions on putting the lift truck on blocks. ing capscrews have been removed.
4. Remove the drive tire lug nuts and remove the
drive tire. CAUTION
Check that cables, hoses, and wires do not in-
5. Tag and disconnect the electric park brake con-
terfere with the removal of the transaxle as-
nector from the main wiring harness.
sembly.
6. Tag and disconnect the motor leads from the ter-
12. Remove the five capscrews and washers securing
minals on the traction motor.
the transaxle to the lift truck frame. Carefully
7. Tag and disconnect the traction motor tempera- lower the transaxle assembly from the lift truck
ture and speed sensors at the traction motor. frame using the floor jack.
8. Drain the oil from the transaxle housing:

WARNING
a. Place a suitable container under the The transaxle and traction motor assemblies
transaxle. are heavy. Be sure that all lifting devices are
suitable and of adequate capacity to lift the
b. Remove the oil fill plug on the housing cover transaxle and traction motor.
beside the traction motor.
13. Transfer the transaxle assembly from the floor
c. Remove the drain plug from the bottom of the jack onto a clean, smooth, and level workbench
housing. See Figure 7. using an overhead lifting device.
CAUTION
cal environmental regulations.
5
Transaxle Assembly 1300 SRM 1074
DISASSEMBLE
CAUTION
Traction Motor and Covers The transaxle is heavy and can be difficult to
stabilize when positioned with the studs down.
WARNING Securely support the transaxle in a stable posi-
tion during these procedures.
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using 4. Carefully position the transaxle with the drive
cleaning solvents, always follow the solvent tire mounting studs down. Support the transaxle
manufacturer’s recommended safety proce- with wooden blocks to stabilize.
dures.
5. Remove the eight socket head capscrews holding
WARNING the cover to the housing. See Figure 9.
The traction motor is heavy. Be sure that all NOTE: The cover is aligned to the housing with
lifting devices are suitable and of adequate ca- dowel pins. Carefully pry the cover from the housing
pacity to lift the traction motor. equally on both sides until it is clear of the dowel
1. Remove the four capscrews and washers mount- pins.
ing the traction motor to the transaxle. See Fig- 6. Separate the cover from the housing. Disassem-
ure 8. ble the cover. Refer to Figure 9.
a. Remove the snap ring (11) from the traction

motor input (6) on the cover.
b. Remove the spacer (9) and the O-ring (8) from

the cover.
c. Remove the seal (10) from the spacer (9).
d. Remove the shims (7) and race (4).
NOTE: Removing the cap from the reduction gear

bearing flange is destructive to the cap.
e. Remove the cap (20) from the reduction gear

bearing flange of the cover.
f. Remove the snap ring (19) from the traction

1. RIGHT SIDE TRANSAXLE motor input (6) on the cover.
2. OIL FILL PLUG
3. TRACTION MOTOR g. Remove the spacer (18) and the O-ring (17)
4. PARKING BRAKE from the cover.
5. FRAME
h. Remove the shims (16) and race (14).
Figure 8. Traction Motor Mounting
2. Remove the traction motor from the transaxle.
3. Use solvent to clean the outside of the transaxle

before disassembly.
6
1. TRANSAXLE HOUSING 11. SNAP RING

2. LOWER INPUT BEARING AND RACE 12. LOWER REDUCTION BEARING AND RACE
3. INPUT GEAR 13. REDUCTION GEAR
4. UPPER INPUT BEARING AND RACE 14. BEARING AND RACE
5. COVER 15. REDUCTION FLANGE
6. INPUT FLANGE 16. SHIMS
7. SHIMS 17. O-RING
8. O-RING 18. SPACER
9. SPACER 19. SNAP RING
10. SEAL 20. CAP
Figure 9. Transmission Housing and Gears
Brake Assembly and Gears removed. Spring washers must be replaced

when the brake is dissembled.
CAUTION 1. Remove the brake assembly components from
Use care removing the brake disks and separa- the mounting dowels one piece at a time and
tors. These parts are matched, and if reused, stack or position them to maintain the correct
must be installed in the same order they were order. See Figure 10.
7
1. SOCKET HEAD CAPSCREW 9. BRAKE PISTONS

2. HOUSING 10. DOWEL, BRAKE
3. PLUG 11. PRESSURE PLATE
4. PLUG 12. SPRING WASHERS
5. BRAKE BLEED VALVE 13. BRAKE DISC
6. TRUNNION CAP 14. COUNTER PLATES
7. SOCKET HEAD CAPSCREW 15. DOWEL, COVER
8. O-RING 16. COVER
Figure 10. Brake Assembly

c. Carefully apply compressed air into the
CAUTION brake line port to force the brake pistons
The following procedure may cause the pistons out of the housing or use a strong magnet or
and oil to forcefully eject from the housing. Use suction cup to lift pistons from housing.
caution when removing the pistons. Always
wear safety glasses. d. Recover the brake pistons and clean up any
spilled oil immediately.
2. Remove the brake pistons:
NOTE: Be careful not to damage the gear teeth when
a. Cover the brake pistons using a clean shop removing the reduction gear and input gear.
cloth to catch the pistons and oil when
ejected. 3. Remove the input gear assembly from the hous-
ing. See Figure 9.
b. Remove the plug from the brake line port.
8
4. Remove the upper and lower bearing cones from 7. Remove the upper and lower bearing cones from
the input gear using an appropriate puller. the reduction gear using an appropriate puller.
5. Remove the lower input race from housing. 8. Remove the lower reduction race from the plane-
tary carrier.
6. Remove the reduction gear from housing. This
will expose the planetary reduction gear set. Planetary Gears and Drive Axle
Refer to Figure 11, for the following procedures.
1. CAPSCREW 11. RING GEAR

2. SPACER 12. INNER OUTPUT (BEARING AND RACE)
3. SHIMS 13. PLANETARY CARRIER
4. O-RING 14. LOWER REDUCTION BEARING
5. WASHER 15. LOWER THRUST PLATE
6. WHEEL HUB 16. BUSHINGS
7. STUD 17. NEEDLE BEARINGS
8. AXLE SEAL 18. PLANET GEAR
9. OUTER OUTPUT (BEARING AND RACE) 19. UPPER THRUST PLATE
10. HOUSING 20. SNAP RING
Figure 11. Output Shaft
9
13. Remove the planetary carrier from the housing.

WARNING
Be careful when installing/removing snap 14. Remove inner output bearing cone from the plan-
rings. Use snap ring pliers. Always wear pro- etary carrier using an appropriate puller.
tective clothing and eye protection.
15. Remove both output bearing races from the hous-
1. Remove the snap rings from the gear pins. ing.
NOTE: The chamfer around the edge of the holes in

the thrust plate MUST BE positioned toward the CAUTION
hub. Make note of thrust plate orientation for re- Removal of the ring gear is destructive to the
assembly. ring gear.
2. Remove the upper thrust plate. 16. If removal is necessary, have the ring gear ex-
tracted by a professional machinist. The position
3. Remove the planet gears from the gear pins. of the ring gear requires special training and in-
tricate equipment to replace without damaging
4. Remove the needle bearing assemblies from the the housing. If there is considerable damage to
gear pins. other internal components of the transmission,
NOTE: The chamfer around the edge of the holes in total replacement of the transmission may be a
the thrust plate MUST BE positioned toward the consideration. Discuss the repair options with
hub. Make note of thrust plate orientation for re- your supervisor. Remove the ring gear ONLY if
assembly. inspection determines that replacement is neces-
sary. See Clean and Inspect.
5. Remove the lower thrust plate.
CLEAN AND INSPECT
6. Remove bushings from gear pins if necessary.
Clean and inspect all parts for any signs of wear,
7. Securely support the housing in a vise or other cracks, or other defects. Carefully inspect all bear-
suitable holding device. Position the housing to ings to ensure smooth operation as the bearing is ro-
allow easy access to the end of the wheel hub. tated. Check bearing races for grooves, pitting, or
excessive wear. Check gear teeth for cracks or any
signs of excessive wear. Replace seals and any part
CAUTION
showing signs of wear or other defects.
Use a prybar wedged between the studs to hold
the wheel hub stationary. Install lug nuts to the 1. Inspect the splines of the planetary carrier for
studs to protect the threads from the prybar. any signs of wear on the spline teeth. If damage
is noted, replace the planetary carrier.
8. Remove the capscrew from the wheel hub. Use
a prybar wedged between the studs to hold the 2. Inspect the planetary carrier for damage and
wheel hub stationary. check for smooth operation. If the planetary
carrier bearing is damaged or does not rotate
9. Remove the spacer, shims, and O-ring from be- smoothly, remove the bearing using an appropri-
hind the capscrew. ate bearing puller. Replace the bearing and race.
NOTE: Removal of the wheel hub is destructive to the 3. Inspect the internal splines of the wheel hub for
axle seal. signs of damage or wear. If damage or wear is
10. Remove the wheel hub, output bearing, and axle noted, replace the wheel hub.
seal from the housing. 4. Inspect the output shaft bearings for damage
11. Remove the outer output bearing cone from the and check for smooth operation. If the planetary
hub. carrier bearing is damaged or does not rotate
smoothly, replace the bearing and race.
12. Remove the axle seal parts from the housing and
from the hub.
10
5. Inspect the planet gear needle bearings and bear-

ing seats for damage and check for smooth oper- CAUTION
ation. If the needle bearings show any signs of Do not use excessive heat to warm the bearing.
damage or wear, replace them and the bearing Heating the bearing beyond specification can
seats. weaken the metal.
6. Inspect the reduction gear bearing for damage 3. Heat the output shaft outer bearing cone at ap-
and check for smooth operation. If the bearing is proximately 85 C (185 F) for 10 minutes to pre-
damaged or does not rotate smoothly, replace the pare for installation.
bearings and races. Remove the bearing races
from the housing using an appropriate puller. NOTE: Quickly install bearing, seal, and hub before
the bearing cools.
7. Inspect the ring gear for chips, cracks, and other
signs of damage or wear. Have the ring gear re- 4. Place the output shaft outer bearing cone into the
moved and installed by a professional machinist, race using heat protective gloves.
if replacement is necessary. See Disassemble -
NOTE: Once the axle seal is installed, it cannot be
Planetary Gears and Drive Axle, Step 16.
removed without destroying the seal.
NOTE: If there is considerable damage to the ring
5. Install the axle seal into the housing. Be careful
gear and other internal components of the transmis-
not to damage the seal during installation.
sion, total replacement of the transmission may be a
consideration. Discuss the repair options with your 6. Install the wheel hub into the housing through
supervisor. the seal and bearing. Make sure the hub is com-
pletely installed and allow the bearing cone to
8. Remove any sealant from the mating surfaces of
cool before continuing.
the housing and cover. Clean the mating surfaces
of all oil, dirt, and grease to ensure proper seal-
ing. CAUTION
Do not use excessive heat to warm the bearing.
ASSEMBLE Heating the bearing beyond specification can
weaken the metal.
Planetary Gears and Drive Axle
7. Heat the output shaft inner bearing cone at ap-
1. Install a new ring gear into the housing, if re- proximately 85 C (185 F) for 10 minutes to pre-
moved. The housing must be heated to 180 C pare for installation.
(356 F) before the ring gear can be installed us-
ing a press. It is advisable to have the ring gear 8. Install the inner output shaft bearing onto the
installed by a professional machinist, or replace planetary carrier using heat protective gloves.
the complete transaxle assembly. Make sure the bearing is completely seated and
allow the bearing cone to cool before continuing.
WARNING 9. Install the planetary carrier into the housing
Allow the housing to cool to room temperature by sliding the planetary carrier splines into the
before proceeding from this point. wheel hub.
NOTE: Secure the transaxle housing in a vise or an
appropriate mounting device. Refer to Figure 11 for CAUTION
the following procedures. Use a prybar wedged between the studs to hold
the wheel hub stationary. Install lug nuts to the
2. Install the inner and outer output bearing races studs to protect the threads from the prybar.
into the housing using an appropriate driver.
NOTE: Install the shims as removed or begin with a
12 mm shim packing if original shims are not avail-
able.
11
10. Install the thrust washer, O-ring, shim(s), NOTE: The chamfer around the edge of the holes in
washer, and capscrew to the wheel hub. Torque the thrust plate MUST BE positioned toward the
the capscrews to 280 N•m (207 lbf ft). hub.
11. Check the hub assembly’s rotating torque: 17. Install the outer thrust plate over the gear pins
and install the snap rings on each pin.
a. Install a variable type torque wrench with
proper-size socket onto the wheel hub cap- Brake Assembly and Gears
screw.
Refer to Figure 10 for the following procedures.
b. Slowly turn the torque wrench clockwise to
begin turning the wheel hub. 1. Install the lower input bearing race into the
housing using an appropriate driver.
c. While rotating the drive wheel hub at a slow
and consistent speed, check the amount of 2. Install the lower reduction bearing race into the
torque registered on the torque wrench. planetary carrier using an appropriate driver.
d. If the torque registered on the torque wrench

is more than 4.5 N•m (40 lbf in). Remove the CAUTION
capscrew from the wheel hub and increase Do not use excessive heat to warm the bear-
the shimming by 0.05 mm. Repeat steps ings. Heating the bearings beyond specifica-
Step 10 and Step 11. tion can weaken the metal.
e. If the torque registered on the torque wrench 3. Heat the upper and lower reduction bearing
is less than 3.2 N•m (28 lbf in). Remove the cones and the upper and lower input bearing
capscrew from the wheel hub and decrease cones at approximately 85 C (185 F) for 10 min-
the shimming by 0.05 mm. Repeat steps utes to prepare for installation. Quickly install
Step 10 and Step 11. heated bearings for best results.
12. Turn the housing down onto the wheel hub studs 4. Place the lower reduction bearing cone into the
and securely support the housing, so it is stable race seated in the planetary carrier using heat
and cannot fall. protective gloves.
CAUTION CAUTION
Do not use excessive heat to warm the bearing. Be careful not to damage reduction gear teeth
Heating the bearing beyond specification can when installing the reduction gear.
weaken the metal.
5. Install the reduction gear to the planet gear set.
13. Heat the gear pin bushings at approximately Make sure the gear shaft is seats in the bearing
85 C (185 F) for 10 minutes to prepare for instal- assembly.
lation.
6. Install the upper reduction bearing cone to the
14. Install bushings to the gear pin shafts using heat reduction gear using heat protective gloves.
protective gloves. After installation, allow them
to cool to room temperature before proceeding. 7. Install the upper and lower input bearing cones
to the input gear using heat protective gloves.
NOTE: The chamfer around the edge of the holes in
the thrust plate MUST BE positioned toward the 8. Install the input gear into the housing. Check
hub. that the input gear properly meshes with the re-
duction gear.
15. Install the inner thrust plate over the gear pins.
NOTE: Always use new O-rings when removing the
16. Install the gear pin needle bearings onto the brake pistons. Lubricate the O-rings and brake pis-
bushings and install the planet gears. tons with a thin layer of grease for assembly.
9. Install new O-rings into the housing.
12
10. Install the brake pistons into the housing. e. Install O-rings into the reduction bearing
and input bearing flanges of the cover.
11. Install the brake dowels into the housing.
f. Install races into the reduction bearing and
input bearing flanges of the cover until
CAUTION seated on bearing cones.
If reinstalling the old brake discs, the brake
discs parts be reassembled in the EXACT orien- NOTE: Determining the preload requirements re-
tation they were removed from the transaxle. quires the use of several special tools (see Figure 12)
Always use new spring washer when assem- in conjunction with some specific conventional tools.
bling the brake. Refer to Table 1 and Table 2 for information regard-
ing tools needed to determine preload requirements.
12. Install the brake disc assembly to the brake dow-
els:
a. Install the pressure plate onto the dowels.
b. Install the first sets of new spring washers

onto each brake dowel.
c. Install a brake disc and then a counter plate.
d. Install the next sets of new spring washers

e. Install the brake disc and then a counter

plate.
f. Install the final sets of new spring washers

g. Install the final brake disc.
Traction Motor and Covers

A. COUPLER PIN
1. Install cover to housing: B. GAUGE
C. SPECIAL WRENCH
a. Clean the mating surfaces of the housing and D. TEMPLATE
cover of all sealant, oil, and dirt.
Figure 12. Special Tools
b. Apply a continuous bead of Loctite™ 510
around the mating surface of the housing Table 1. Special Tools
circling all dowel and bolt holes.
Special Tools
c. Align the cover to the dowel pins.
Description Hyster Part Number
NOTE: Press the cover down onto the housing evenly
and HOLD to compress the brake assembly spring Coupler Pin 1564269
washers. DO NOT force the cover. Gauge 1564270
d. Apply Loctite™ 270 to the threads of the Template 1564271
eight, socket head capscrews and install to 1564272
Special Wrench
secure the cover to the housing. Torque to
120 N•m (89 lbf ft).
13
Table 2. Conventional Tools (6) Measure from the top of the gauge to
the plunger using a depth gauge. This
Conventional Tools is value A.
Long Shaft Allen Wrench (6 mm) (7) Remove gauge from the template.
Depth Gauge
b. Determine the input bearing preload (value
Open-end Wrench B):
(1) Insert the coupler pin into the input

2. Measure to find the bearing preload require-
gear.
ments using special tools and a depth gauge.
(2) Place the gauge into the input flange.
a. Preset the gauge and determine value A:
Secure using snap ring.
(1) Install the gauge into the template. See
(3) Install special wrench to the gauge.
Figure 13.
(4) Hold the gauge stationary with an open-
end wrench.
(5) Turn the special wrench clockwise until

the plunger of the gauge touches the top
of the bearing.
(6) Remove the special wrench from the

gauge.
(7) Insert an Allen wrench (6 mm) through

the gauge into the coupler pin and turn
to rotate the gears several times to en-
sure the bearings are properly seated.
(8) Repeat steps Step (3) through Step (7).

A. PRESETTING THE GAUGE (VALUE "A")
B. INSTALLING THE GAUGE TO THE INPUT NOTE: It is preferable to take preload measurements
BEARING FLANGE (VALUE "B") in millimeters to avoid conversions when calculating
C. INSTALLING THE GAUGE TO THE REDUCTION
BEARING FLANGE (VALUE "C") shims.
Figure 13. Using the Gauge (9) Measure from the top of the gauge to
the plunger using a depth gauge. This
(2) Install the special wrench to the gauge. is value “B”.
(3) Hold the gauge stationary with an open- (10) Subtract value A (see Step a) from value
end wrench. B and add 0.05 mm. This is the input
bearing preload.
(4) Turn the special wrench clockwise un- (B A)+0.05 mm = Input Bearing
til the plunger of the gauge touches the Preload
bottom of the template.
NOTE: The coupler pin should not be removed until
(5) Remove the special wrench from the after the reduction bearing preload has been deter-
gauge. mined.
NOTE: It is preferable to take preload measurements (11) Remove snap ring and gauge from the
in millimeters to avoid conversions when calculating cover.
shims.
14
c. Determine the reduction bearing preload b. Measure shims for individual thicknesses
(value "C"): and assemble shims, which together add up
to the necessary reduction bearing preload.
(1) Place the gauge into the reduction bear- Refer to Step 2, above. Install shims into the
ing flange. Secure using snap ring. reduction bearing flange of the cover.
(2) Install special wrench to the gauge. c. Install seal (10) into spacer (9).
(3) Hold the gauge stationary with an open- d. Install seal and spacer into the input bearing
end wrench. flange of the cover.
(4) Turn the special wrench clockwise until e. Install spacer (18) into the reduction bearing
the plunger of the gauge touches the top flange of the cover.
of the bearing.
f. Install snap rings (11 and 19) into the reduc-
(5) Insert an Allen wrench (6 mm) into the tion bearing and input bearing flanges of the
coupler pin in the input bearing and cover.
turn to rotate the gears several times to
ensure the bearings are properly seated g. Install the cap (20) with Loctite™ 270 to the
and are not binding. reduction bearing flange of the cover using
an appropriate driver.
(6) Repeat steps Step (3) through Step (5).
4. Install the traction motor to the transaxle:
NOTE: It is preferable to take preload measurements
in millimeters to avoid conversions when calculating a. Position the traction motor to the transmis-
shims. sion and align the capscrew holes.
(7) Measure from the top of the gauge to b. Apply Loctite™ 271 to the capscrew threads
the plunger using a depth gauge. This and install to secure traction motor to trans-
is value “C”. mission.
(8) Remove snap ring and gauge from the c. Torque to 48 N•m (35 lbf ft).
cover.
INSTALL
(9) Remove the coupler pin from the input
gear.
WARNING
(10) Subtract value A (see Step a) from value The transaxle and traction motor assembly
C and add 0.05 mm. This is the reduc- are heavy. Be sure that all lifting devices are
tion bearing preload. suitable and of adequate capacity to lift the
(C A)+0.05 mm = Reduction Bearing transaxle and traction motor.
Preload
1. Place the transaxle assembly on a floor jack.
For the following procedures, refer to Figure 9. Make sure the assembly is balanced and properly
supported so it will not fall during installation.
3. Assemble cover:
2. Carefully raise and align the transaxle with the
NOTE: Round the bearing preload values UP to the mounting holes in the lift truck frame using the
nearest 0.05 mm when selecting shims. floor jack.
a. Measure shims for individual thicknesses 3. Remove the cap and plug from the brake line and
and assemble shims, which together add up brake line port fitting. Install the brake line to
to the necessary input bearing preload. See the brake line port fitting.
Step 2, above. Install shims into the input
bearing flange of the cover.
15
4. Apply Loctite™ 271 to the five socket head 9. Bleed the service brakes. See Brake System
capscrews and washer Install capscrews with 1800 SRM 1076.
washers through the transaxle and into the
mounting holes in the frame. Torque to 220 N•m 10. Install the drive tire and wheel assembly to
(162 lbf ft). the wheel hub. Install lug nuts and torque to
170 N•m (125 lbf ft).
5. Install the power cables to the traction motor
studs as removed. 11. Lower lift truck from the blocks. See Periodic
Maintenance 8000 SRM 1079.
6. Install the temperature and speed sensor connec-
tors at the traction motor as removed. WARNING
7. Connect the parking brake connectors and the Make sure the resistor used to discharge the ca-
traction motor connectors. pacitor(s) has been removed BEFORE connect-
ing the battery connector.
8. Fill the transaxle with oil to the proper level:
12. Connect the battery connector, turn the key
a. Install the oil drain plug. Torque to 40 N•m switch to the ON position, and test the lift truck
(30 lbf ft). for proper operation.
b. Fill the transaxle until the oil reaches the 13. Install the mast to the lift truck. See Mast, Re-
bottom of the oil fill hole. pairs 4000 SRM 522.
c. Install the oil fill plug. Torque to 40 N•m

(30 lbf ft).
Troubleshooting
One drive wheel will not Damage to traction motor. Damage Repair traction motor. Repair gear
move. to gear reduction system. reduction system in the transaxle.
Electrical system fault. Troubleshoot the electrical system.
Noise during operation that Bearing damage. Replace damaged bearings.

is not normal.
Low oil level. Add oil to the correct level.
Noise continues after correct oil Check for wear and damage in the
level. gear reduction system.
Ring and pinion backlash is not prop- Check the backlash.

erly adjusted.
Noise continues. Check that the ring and pinion is a

matched gear set.
16
Oil leaks. Damaged O-rings or oil seals. Replace the O-rings and oil seals as
necessary. Use new O-rings and oil
seals if the transaxle is disassembled
for repairs.
Drain or fill plug loose. Tighten plug. Torque to 40 N•m

(30 lbf ft).
Oil being ejected through breather Remove oil fill plug and allow excess
due to overfilling. oil to drain until level with bottom of
oil fill hole.
17
NOTES
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18

STEERING SYSTEM
J1.6-2.0XMT (J30-40ZT) [J160]
PART NO. 1554628 1600 SRM 1075

SAFETY PRECAUTIONS

on electric lift trucks.
• Disconnect the battery ground cable on internal combustion lift trucks.
nance section.
manual:
WARNING
CAUTION
Steering System Table of Contents
TABLE OF CONTENTS
Introduction........................................................................................................................................................ 1
General ........................................................................................................................................................... 1
Description of Operation.................................................................................................................................... 3
Steering Pressure Check ................................................................................................................................... 3
Operation Check ................................................................................................................................................ 5
Steering Wheel and Column.............................................................................................................................. 5
Steering Column Covers................................................................................................................................ 5
Remove....................................................................................................................................................... 5
Install ......................................................................................................................................................... 5
Steering Column Components ...................................................................................................................... 6
Remove....................................................................................................................................................... 6
Install ......................................................................................................................................................... 9
Steering Control Unit Assembly ....................................................................................................................... 10
Power Steering Pump and Motor ...................................................................................................................... 10
Description ..................................................................................................................................................... 10
Remove ........................................................................................................................................................... 10
Install ............................................................................................................................................................. 12
Disassemble ................................................................................................................................................... 12
Assemble ........................................................................................................................................................ 12
Steering Actuator Components ......................................................................................................................... 14
Steer Tire and Wheel Assembly.................................................................................................................... 14
Remove....................................................................................................................................................... 14
Install ......................................................................................................................................................... 14
Wheel Hub Assembly..................................................................................................................................... 14
Remove....................................................................................................................................................... 14
Install ......................................................................................................................................................... 15
Steering Axle Assembly................................................................................................................................. 15
Remove....................................................................................................................................................... 15
Clean .......................................................................................................................................................... 17
Install ......................................................................................................................................................... 17
J1.6-2.0XMT (J30-40ZT) [J160]

"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
Introduction
GENERAL and adjustments that are not correct can cre-
This section contains the description and repair pro- erate a lift truck that needs repairs. Report
cedures for the steering system. Components cov- the need for repairs to your supervisor imme-
ered are the steering wheel and column assembly, diately. If repair is necessary, attach a DO NOT
steering control unit, pump and motor assembly, and OPERATE tag to the steering wheel. Remove
steering actuator. Some parts associated with the the key from the key switch.
steering system are not covered in this section be-
cause they are more closely associated with other sys-
tems. See the following list for information not in- WARNING
cluded in this section. Disconnect the battery before opening the
See the section Periodic Maintenance 8000 drive unit compartment cover or inspecting or
SRM 1079 for information on the regular sched- repairing the electrical system. If a tool causes
uled maintenance. a short circuit, the high current flow from the
See the section Electrical System 2200 SRM battery can cause personal injury or property
1078 for information on wiring and power supply damage.
to the steering pump motor.
See the section Hydraulic System 1900 SRM WARNING
1077 for information on the hydraulic tank and
Some checks and adjustments are done with
system.
the battery connected. Do not connect the
Throughout this section, forward will refer to travel battery until the procedure tells you to do so.
in the direction of the forks and left and right deter- Never have any metal on your fingers, arms,
mined by an operator sitting in the seat facing for- or neck. Metal items can accidentally make an
ward. See Figure 1. electrical connection and cause injury.
WARNING
Before performing any tests or adjustments,
block the lift truck to prevent unexpected
movement.
WARNING
The capacitor in the transistor controller(s)
is disconnected. To prevent an electrical shock
and personal injury, discharge the capacitor(s)
been disconnected.
A. LEFT SIDE C. FORWARD
B. RIGHT SIDE TRAVEL
CAUTION
Figure 1. Truck Orientation To avoid controller damage, always disconnect
the battery, discharge the capacitor(s), and
DISCHARGING THE CAPACITORS never put power to the controller while any
power wires are disconnected. Never short
WARNING any controller terminal or motor terminal to
have both authorization and training. Repairs
1
the battery. Make sure to use proper proce- 4. On the premium controller, also connect a 200-
dure when servicing the controller. ohm, 2-watt resistor across the controller’s P+
and B terminals for 10 seconds using insulated
1. Block load wheels to prevent lift truck from mov- jumper wires. See Figure 3.
ing.
2. Turn key switch to OFF position and disconnect connecting the battery.
the battery.
WARNING
NOTE: Some lift trucks are equipped with a pre-

mium controller, which controls the hydraulic motor,
as well as the traction motors.


3. INSULATED JUMPER WIRES

(Optional)


(Standard)
2
1600 SRM 1075 Steering Pressure Check
Description of Operation
Turning the steering wheel actuates three main More rotation of the steering wheel causes the spool
parts of the steering control unit: to rotate the pin. This action causes the rotation of
• Spool for the control section the sleeve and the rotor in the metering section. The
• Sleeve for the control section oil then flows to one side of the steering unit. Hy-
• Rotor in the metering section draulic oil from the other side of the steering unit re-
turns through the control section of the steering con-
When the steering wheel is not moving, the spool trol unit.
and sleeve are held in the neutral (center) position
by springs. During this time, oil flows freely through When the steering wheel stops moving, the metering
the steering control unit. The oil does not flow to the action in the metering section also stops. The neutral
steering unit. position springs return the sleeve to the neutral po-
sition. When this action occurs, the pressure stays in
As the steering wheel is turned, the spool begins to the steering cylinder to keep the steer wheels in po-
rotate. The springs try to move the sleeve to keep the sition. Oil from the pump flows through the steering
neutral position between the spool and sleeve. How- control unit to the tank or other parts of the system.
ever, the force necessary to turn the rotor is greater To return the steering wheel to the straight position,
than the pressure of the springs. The springs bend, the steering wheel must be rotated in the opposite
letting the spool move a small amount within the direction. The steering control unit will operate as
sleeve. The spool stops moving when it touches the described, but all parts will rotate in the opposite di-
center pin. In this position, the holes in the sleeve rection.
and the spool are aligned. Oil coming into the con-
trol unit flows to the metering section.
Steering Pressure Check

The steering system can be evaluated by checking the b. Remove floor mat and floor plates.
system pressure. Using a hydraulic pressure gage,
tee into the steering pressure hose and check the sys- c. Remove the steering pressure hose from the
tem pressures. See Figure 4. pump pressure port fitting.
For the following procedures, you will need a hy- d. Install the 90 degree fitting end of the exten-
draulic pressure gage with a capacity of at least sion hose onto the pump pressure port fitting.
100 bar (1450 psi) connected to a flared tee fitting
e. Install the steering pressure hose and the ex-
(male, number 6). You will also need an exten-
tension hose to the tee fitting attached to the
sion hose [a hydraulic hose approximately 2 feet in
hydraulic pressure gage.
length with a 90 degree, flared swivel fitting (female,
number 6) on one end and a straight flared fitting 2. Connect the battery. Have a technician sit in the
(female, number 6) for connecting to the tee fitting seat and turn the key switch to the ON position.
on the other end].
3. Have the technician operate the steering control
NOTE: The correct relief valve pressure is 75.8 unit by rotating the steering wheel to its full left
±2.5 bar (1100 ±36 psi). or full right position. Check that maximum pres-
sure is 75.8 ±2.5 bar (1100 ±36 psi).
1. Install a hydraulic pressure gauge between the
power steering pump and the steering control 4. If pressure is greater than 78.3 bar (1136 psi), re-
unit. See Figure 4. place steering control unit. See Steering Control
Unit Assembly.
a. Turn the key switch to the OFF position and
disconnect the battery.
3
Steering Pressure Check 1600 SRM 1075
5. If pressure is less than 73.3 bar (1064 psi), the

steering pump may be at fault. Check the steer-
ing pump for proper hydraulic pressure:

b. Install a gate valve (open) between the steer-

ing pressure hose and the tee fitting.
c. Connect the battery. Have a technician sit in

the seat and turn the key switch to the ON
position.
d. Have the technician operate the steering con-

trol unit by rotating the steering wheel to its
full left or full right position.
e. SLOWLY close the gate valve to restrict the

flow of hydraulic oil until the pressure gage
rises to 73.3 bar (1064 psi) while the steering
wheel is in its full left or full right position.
f. If the steering system pressure does not rise

above 73.3 bar (1064 psi), the pump is not
performing properly. Repair or replace the
steer pump. See Steering Control Unit As-
sembly.
6. When pressure checks are complete:

b. Remove extension hose from pump pressure

port fitting.
1. STEERING PRESSURE HOSE
2. PUMP PRESSURE PORT FITTING c. Remove steering pressure hose from tee. Re-
3. STEERING PUMP MOTOR
4. STEERING PUMP move gate valve if installed.
Figure 4. Steering Pressure Check d. Install steering pressure hose to pump pres-
sure port fitting.
e. Install floor plates and floor mat.
7. Perform an operation check before returning to

service. See Operation Check.
4
1600 SRM 1075 Steering Wheel and Column
Operation Check
The purpose of this check is to make sure the steer- trunnion to its stop in the other direction. Check
ing trunnion turns the correct degrees of its rotation that the steering wheel turns the trunnion smoothly.
(approximately 180 degrees). Put the lift truck on The face of the wheel should be approximately par-
blocks so the weight of the lift truck is removed from allel to the frame plate at the back of the battery
the steering trunnion. compartment when the steering trunnion is rotated
fully in each direction to its stops.
Operate the power steering system. Rotate the
trunnion to its stop in one direction, then rotate the
Steering Wheel and Column

This procedure is for the removal of all components
of the steering wheel and column assembly. See Fig-
ure 5. It may not be necessary to remove all compo-
nents for a repair procedure. Perform only the steps
necessary to complete the repair.
STEERING COLUMN COVERS

Remove
For the following procedures, refer to Figure 6.
1. Turn the key switch to the OFF position. Discon-

nect the battery connector.
2. Disassemble the covers by removing six screws

(11) securing covers together and two screws (9)
holding the latch release. Carefully separate the
covers. See Figure 6.
3. Disconnect wiring harness from the key switch

and remove key switch from rear cover if neces-
sary.
Install
1. Install key switch and static ground strap to
lower cover, if removed. Connect wiring harness
to key switch.
2. Install the covers by assembling each half around

the steering column and installing six screws.
See Figure 6. 1. STEERING WHEEL
2. STEERING SHAFT
3. STEERING CONTROL UNIT
3. Install latch release and secure using two screws 4. LATCH RELEASE
(9). 5. ADJUSTING LATCH MECHANISM
6. COLUMN COVERS
4. Reconnect the battery connector and test for 7. COLUMN BASE
proper operation.
Figure 5. Steering Wheel and Column
5
Steering Wheel and Column 1600 SRM 1075
1. STEERING KNOB 6. STATIC GROUND STRAP 11. SCREW

2. STEERING WHEEL CAP 7. KEY SWITCH 12. PLUG
3. STEERING WHEEL 8. LATCH RELEASE 13. PLUG
4. UPPER COVER 9. SCREW
5. COLUMN BRACKET 10. LOWER COVER
Figure 6. Steering Column Covers
STEERING COLUMN COMPONENTS 2. Remove the steering lock nut and, using the heel
of your hand, bump upward on each side of the
Remove steering wheel to remove.
See Figure 7 and Figure 8 for the following proce- 3. Tag and disconnect hoses from bottom of steering
dures. control unit. Cap ports and plug hoses to mini-
mize leakage.
1. Using a hammer and a punch, gently tap upward
around the edges of the steering wheel cap to re- 4. Tag and disconnect wires and remove the horn
move from the steering wheel. contacts and the encoder on the steering column.
6
5. Tag and disconnect wires and remove the direc- 11. Remove pivot pin and bracket spring from col-
tional switch plate and directional control lever umn base.
assembly if so equipped. See Figure 7.
6. Remove the four capscrews (25), lockwashers

(24), and washers (23) securing steering shaft
and steering control unit assembly to column
bracket. Remove assembly from steering col-
umn. See Figure 8.
NOTE: Mark the steering control unit and the steer-

ing shaft for proper alignment during assembly.
7. Separate steering shaft from steering control

unit by removing four capscrews (29) and lock-
washers (30) securing units together.
8. Remove tilt limit capscrew (10) and lock nut (11).
WARNING
Tilt return spring is under tension. Be careful
when servicing tilt assembly components. Al-
ways wear eye protection.
9. Remove steering column tilt adjustment linkage

if necessary.
a. Tilt the steering column to its upright posi-

tion.
b. Move the bracket spring to relieve tension

using a prybar.
c. Compress and hold the tilt lock spring while

removing the spring guide shaft, tilt lock
spring, and cup washer.
d. Remove cotter pin and the lock pivot pin.
e. Remove tilt lock bracket from steering col-

umn.
NOTE: Support column bracket with a sling and 1. DIRECTIONAL CONTROL LEVER ASSEMBLY
overhead lifting device or have an assistant hold the 2. STEERING COLUMN
bracket. 3. DIRECTIONAL SWITCH PLATE
4. ATTACHING HARDWARE
10. Release pivot shaft from retainer brackets by re- 5. ATTACHING HARDWARE
moving capscrews (13) and washers (14) and re-
Figure 7. Directional Controls
move column bracket from truck.
7
Steering Wheel and Column 1600 SRM 1075
Figure 8. Steering Column
8
Legend for Figure 8

1. DIRECTIONAL LEVER GUIDE 16. PIVOT PIN
2. UPPER COVER 17. STEERING LOCK NUT
3. LOWER COVER 18. STEERING WHEEL CAP
4. SCREW 19. STEERING WHEEL
5. TILT LEVER 20. TILT LOCK BRACKET
6. TILT LEVER SCREWS 21. LOCK PIVOT PIN
7. CUP WASHER 22. COTTER PIN
8. TILT LOCK SPRING 23. WASHER
9. SPRING GUIDE SHAFT 24. LOCKWASHER
10. TILT LIMIT CAPSCREW 25. CAPSCREW
11. LOCK NUT 26. STEERING CONTROL UNIT
12. PIVOT PIN RETAINER 27. STEERING SHAFT
13. CAPSCREW 28. COLUMN BRACKET
14. WASHER 29. CAPSCREW
15. BRACKET SPRING 30. LOCKWASHER
Install 4. Set bracket spring tension at this time.
See Figure 8 for the following procedures. NOTE: Align the steering control unit and the steer-
ing shaft as removed.
1. Install pivot pin (16) and bracket spring (15) to
column base. See Figure 8. 5. Assemble steering shaft to steering control unit
using four capscrews (29) and lockwashers (30)
NOTE: Support column bracket with a sling and to secure together.
overhead lifting device or have an assistant hold the
bracket. 6. Position steering shaft and steering control unit
assembly into steering column. Install four cap-
NOTE: DO NOT set bracket spring tension at this screws (25), lockwashers (24), and washers (23)
time. securing assembly to column bracket.
2. Secure pivot shaft to column bracket by in- 7. Install directional control lever assembly and di-
stalling pivot pin retainers (12) using capscrews rectional switch plate and wiring if so equipped.
(13) and washers (14). See Figure 7.
3. Install steering column tilt adjustment linkage if 8. Remove caps and plugs from hoses and ports.
removed. Connect hoses to bottom of steering control unit
as removed.
a. Position tilt lock bracket to column bracket
and install lock pivot pin (21) and cotter pin 9. Install steering wheel to steering shaft as re-
(22). moved. Install the steering lock nut.
b. Compress and hold the tilt lock spring while 10. Install the horn contacts and the encoder on the
installing the spring guide shaft, tilt lock steering column. Connect wires as removed.
spring, and cup washer.
11. Install cap to the center of the steering wheel.
c. Tilt the steering column to its upright posi-
tion.
d. Install tilt limit capscrew (10) and lock nut

(11).
9
Power Steering Pump and Motor 1600 SRM 1075
Steering Control Unit Assembly

The steering control unit is a metering device that
controls the flow of hydraulic oil to the steering ac-
tuator. See Figure 9. The steering pump and motor
sends pressurized hydraulic oil to the steering con-
trol unit where it is metered out to either side of the
steering actuator. The steering wheel is connected
to the steering control unit by the steering shaft and
controls the position of the steering control unit. The
unit is not serviceable and must be replaced if dam-
aged. Remove the unit from the steering column and
replace with a new unit if necessary. Refer to Steer-
ing Wheel and Column for removal and installation
procedures.
Figure 9. Steering Control Unit
Power Steering Pump and Motor

DESCRIPTION steering pump and motor are mounted to the frame
with rubber isolator mounts. See Figure 10.
The power steering pump and motor are located un-
der the floor plates on the left side of the truck. The 1. Disconnect battery. Remove battery to gain ac-
power steering pump is a single-section gear pump cess to hex head bolts for mounting power steer-
that draws the hydraulic oil from the hydraulic ing pump and motor. Follow the instructions in
tank and directs the oil to the steering control unit the section Periodic Maintenance 8000 SRM
mounted in the steering column. The power steering 1079 or the Operating Manual for battery re-
motor and pump operate when the key switch is ON moval information.
and the operator is on the seat (seat switch closed).
A timer stops the power steering motor 6 seconds 2. Remove floor mat and left side floor plate in the
after the operator is off the seat (seat switch open) operator compartment.
and the key switch is still ON.
REMOVE
The power steering pump and motor must be re-
moved as a unit for servicing the pump. The power
10
1600 SRM 1075 Power Steering Pump and Motor
1. MOTOR 6. LOCKWASHER
2. O-RING 7. LOCKWASHER
3. PUMP 8. CAPSCREW
4. MOUNTING PLATE 9. SPACER
5. CAPSCREW
Figure 10. Pump and Motor Mount Figure
3. Tag and disconnect electrical wires for identifica- 5. Disconnect suction line to power steering pump.
tion at assembly. Disconnect discharge line from power steering
pump. Plug both hydraulic lines and pump ports
4. Drain hydraulic tank. See the section Hy- to prevent dirt from entering hydraulic system
draulic System 1900 SRM 1077. and to prevent hydraulic oil from leaking from
system.
11
Power Steering Pump and Motor 1600 SRM 1075
7. Install battery. Follow the instructions in the

WARNING section Periodic Maintenance 8000 SRM 1079
The power steering pump and motor are or the Operating Manual for battery installa-
heavy. Be sure that all lifting devices (lifts, tion information.
cables, chains, slings, etc.) are suitable and of
adequate capacity to lift the power steering 8. Connect battery, turn key switch to the ON posi-
pump and motor. The power steering pump tion, and test for proper operation.
and motor can weigh approximately 13.6 kg
(30 lb). The power steering motor has ceramic, DISASSEMBLE
permanent magnets. If the motor falls, the
magnets can be damaged. 1. Mark pump and motor to ensure proper align-
ment at assembly. Remove two capscrews and
6. Remove three capscrews, washers, and bracket washers retaining pump to motor. Separate
retaining power steering pump and motor to lift pump from motor. See Figure 11.
truck frame.
2. Remove eight capscrews and washers retaining
7. Carefully lift power steering pump and motor out cover to housing. Carefully separate cover from
of lift truck. housing.
INSTALL 3. Remove gears, drive shaft, keys, spacer, and idler

shaft and gear.
WARNING
The power steering pump and motor are WARNING
heavy. Be sure that all lifting devices (lifts, Be careful when removing or installing snap
cables, chains, slings, etc.) are suitable and of rings. These snap rings can come loose dur-
adequate capacity to lift the power steering ing removal or installation with enough force
pump and motor. The power steering pump to cause an injury. Always use the correct snap
and motor can weigh approximately 13.6 kg ring pliers and wear eye and face protection
(30 lb). The power steering motor has ceramic during removal and installation.
permanent magnets. If the motor falls, the
4. Remove snap rings and needle bearings.
magnets can be damaged.
5. Clean and inspect needle bearings for damage.
1. Carefully locate power steering pump and motor
Inspect gears, idler shaft and gear, and drive
in lift truck.
shaft for erosion or damage. Replace all defec-
2. Align power steering pump and motor and tive parts. Replace oil seal and joints.
brackets with mount holes in frame. Install
capscrews, washers, and nuts to retain pump ASSEMBLE
and motor to lift truck frame. Tighten nuts to
Lubricate all components with clean hydraulic oil be-
25 N•m (18 lbf ft).
fore assembly.
3. Remove plugs from discharge port and dis-
charge line. Install discharge line into pump WARNING
port. Clean and inspect in-line strainer. Re- Be careful when removing or installing snap
place in-line strainer if necessary. Install in-line rings. These snap rings can come loose dur-
strainer in suction line. Install suction line on ing removal or installation with enough force
suction side of pump. to cause an injury. Always use the correct snap
4. Refill hydraulic tank to the proper level. ring pliers and wear eye and face protection
during removal and installation.
5. Install all disconnected electrical wires.
1. Install needle bearings in pump halves. Install
6. Install floor plates. snap rings to retain bearings.
12
1600 SRM 1075 Power Steering Pump and Motor
2. Install spacer on shafts. Install remaining two 4. Install idler shaft and gear in needle bearing of
gears on shafts. upper half of pump. Align and install gear on
drive shaft and key so it mates with idler gear.
3. Install oil seal in upper half of pump. Carefully
install drive shaft through oil seal and needle 5. Ensure housing and cover are properly aligned
bearing. Install keys on drive shaft. and install gasket. Install eight capscrews and
washers retaining housing and cover together.
1. HOUSING 8. SPACER
2. SCREW 9. COVER
3. PLUG 10. OIL SEAL
4. NEEDLE BEARING 11. DRIVE SHAFT
5. KEY 12. GUIDE PIN
6. SNAP RING 13. GASKET
7. GEAR 14. IDLER SHAFT AND GEAR
Figure 11. Power Steering Pump
13
Steering Actuator Components 1600 SRM 1075
Steering Actuator Components

The steering actuator assembly has a horizon- Install
tal shaft and gear assembly (pinion) that extends
through the gear housing, which is mounted in the WARNING
bottom of the counterweight. The pinion is rotated
Lifting and carrying of tires is not recom-
by the horizontal movement of a hydraulic-driven
mended because their weight could be in
gear rack. The power steering pump feeds hydraulic
excess of 45 kg (100 lb). Where applicable, use
oil to the steering control unit, which directs the oil
a wheel or tire dolly to assist in the removal
into either end of the gear housing. The housing acts
and installation of the wheel. Follow the in-
as a cylinder tube. Pistons, at each end, control the
structions in the section Periodic Maintenance
movement of the gear rack.
8000 SRM 1079 or the Operating Manual.
STEER TIRE AND WHEEL ASSEMBLY 1. Align wheel and tire assembly with studs and
install wheel and tire assembly on wheel hub.
Remove
2. Install lug nuts on studs to retain wheel assem-
WARNING bly. Tighten nuts snugly.
Before attempting to remove the steer tire 3. Lower lift truck to floor. Tighten lug nuts to
and wheel assemblies from the steering axle, 170 N•m (125 lbf ft).
put blocks under each side of the frame. The
blocks must prevent the lift truck from falling 4. Remove blocks from wheels. Connect the battery.
and causing injury or damage. Do not place
jacking equipment under the counterweight. 5. After 2 to 5 hours of operation, check all wheel
nuts. Tighten lug nuts in a cross pattern to
NOTE: Perform the following procedures for each 170 N•m (125 lbf ft). When nuts stay tight after
steer tire and wheel assembly. an 8-hour check, the interval for checking the
torque can be extended to 350 hours.
1. Turn steering wheel so steer tire and wheel as-
sembly to be removed is accessible. Turn key WHEEL HUB ASSEMBLY
switch to the OFF position and disconnect the
battery. Remove
2. Block the drive wheels to prevent unexpected NOTE: The instructions are for one wheel hub assem-
movement and apply parking brakes. bly. If necessary, perform the same operation for the
opposite side.
WARNING
1. Remove wheel and tire assembly. See Steer Tire
Do not place jacking equipment under the and Wheel Assembly, Remove.
counterweight.
2. Remove hub cap. Straighten, remove, and dis-
3. Place the rear of the lift truck frame on blocks to card cotter pin. Remove nut, washer, spacer, and
suspend the steer tires off the ground. See How hub assembly.
to Put Lift Truck on Blocks in either the Oper-
ating Manual or the section Periodic Mainte-
nance 8000 SRM 1079. WARNING
Be careful when removing or installing snap
4. Loosen lug nuts retaining steer tire and wheel rings. These snap rings can come loose dur-
assembly. ing removal or installation with enough force
to cause an injury. Always use the correct snap
5. Remove lug nuts and wheel assembly from steer-
ring pliers and wear eye and face protection
ing axle.
during removal and installation.
3. Remove and discard nilos sealing rings from hub.

Use a soft, metal drift to remove bearings.
14
1600 SRM 1075 Steering Actuator Components
4. Inspect bearings for damage. Inspect axle shaft 2. Remove two capscrews that retain rear cover to
for damage or corrosion. Inspect wheel studs for counterweight. Remove rear cover.
damage. Replace all damaged components.
WARNING
Install
The capacitors in the traction controllers can
1. Prior to installation, pack bearings and new nilos hold an electrical charge after the battery is
sealing rings with grease. See the section Peri- disconnected. To prevent electrical shock and
odic Maintenance 8000 SRM 1079 or the Op- injury, discharge the capacitors after discon-
erating Manual for the recommended grease. necting the battery connector and before re-
pairing or replacing any component in the rear
compartment. Wear safety glasses. Make cer-
WARNING tain the battery has been disconnected. Dis-
Be careful when removing or installing snap charge the capacitors in the controllers by con-
rings. These snap rings can come loose dur- necting a 200-ohm, 2-watt resistor across the
ing removal or installation with enough force controller’s POS and NEG terminals (outer two
to cause an injury. Always use the correct snap power cable terminals). DO NOT short across
ring pliers and wear eye and face protection the motor controller terminals with a screw-
during removal and installation. driver or jumper wire. Remove the 200-ohm,
2-watt resistor before reconnecting the battery.
2. Install snap rings in hub to retain bearings.
Make certain snap rings are seated in wheel 3. Discharge controller capacitors.
hub. Install both inner and outer wheel bearings
in hub. Install inner nilos sealing ring. 4. Unscrew cylinder from gear housing. Remove
O-ring from gear housing. See Figure 12.
3. Carefully install hub on axle so seal is not dam-
aged. Install outer nilos sealing ring. 5. Remove piston from inside cylinder.
4. Install spacer and washer on axle. Install slotted 6. Remove two piston guideways and compact seal
nut. Tighten nut to 47 N•m (35 lbf ft). Rotate from piston.
wheel while tightening nut. If necessary, back
off on the nut to align nut and hole in axle shaft. 7. Remove four capscrews that fasten yoke assem-
bly and gear housing shaft assembly. Separate
5. Install new cotter pin. Install hub cap. shaft assembly from yoke assembly.
6. Install wheel assembly. See Steer Tire and Wheel 8. Remove cap from end of wheel hub. Remove cot-
Assembly, Remove. ter pin, nut, and u-disc.
STEERING AXLE ASSEMBLY 9. Remove assembled wheel hub from yoke shaft.
Remove bearings and wheel bolts if necessary.
Remove
10. Remove nilos ring from yoke shaft.
NOTE: The removal instructions listed are performed
with the counterweight, wheels, and tires installed. 11. Remove nut, washer, shims, nilos ring, and bear-
ings from flange shaft.
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.
15
Steering Actuator Components 1600 SRM 1075
1. NUT 12. PISTON 23. BEARING

2. WASHER 13. O-RING 24. WHEEL HUB
3. SHIM 14. LINER 25. BEARING
4. NILOS RING 15. GEAR RACK 26. NILOS RING
5. BEARING 16. HOUSING 27. WHEEL BOLT
6. SHIM 17. SHAFT SEAL 28. CAPSCREW
7. SAFETY RING 18. RACEWAY 29. FLANGE SHAFT
8. SHAFT SEAL 19. CAP 30. NILOS RING
9. PISTON GUIDEWAY 20. NUT 31. BEARING
10. COMPACT SEAL 21. COTTER PIN 32. PLUG SCREW
11. CYLINDER 22. U-DISC
Figure 12. Steering Axle Assembly
16
1600 SRM 1075 Steering Actuator Components
12. Remove flange shaft from gear housing. 3. Install liners into each end of gear housing. In-
stall gear rack through both liners in gear hous-
13. Remove bearing and nilos ring from flange shaft. ing, making sure middle groove of gear rack is
located in middle of gear housing.
14. Slide gear rack out of gear housing. Remove lin-
ers from each end of gear housing. 4. Fill nilos ring with grease and position ring over
flange shaft. Press bearing on flange shaft.
15. Remove safety ring, shaft seals, and bearing
raceway from top and bottom opening of gear 5. Install flange shaft through gear housing. In-
housing if necessary. stall selected shims, bearing, nilos ring, addi-
tional shims, washer, and nut over end of flange
Clean shaft.
WARNING 6. Install five wheel bolts into each wheel hub.

Cleaning solvents can be flammable and toxic Press bearings into each end of wheel hubs. Fill
and can cause skin irritation. When using nilos ring with grease and place it over yoke
cleaning solvents, always follow the solvent shaft. Install assembled wheel hub over yoke
manufacturer’s recommended safety precau- shaft. Fill inside area of wheel hub with grease.
tions and procedures. 7. Install u-disc and nut over end of yoke shaft.
1. Clean all parts in solvent. Tighten nut firmly and secure assembly in place
with cotter pin. Install cap over end of wheel hub.
2. Dry parts with compressed air. Do not dry parts
with a cloth. 8. Assemble yoke assembly to gear housing with
shaft assembly. A pressed pin in yoke will help
3. Make sure all surfaces are free of scratches and to properly align the two assemblies. Fasten the
sharp edges. two assemblies together with four capscrews.
Install 9. Install two piston guideways and a compact seal

over piston. Install piston into cylinder and push
piston to end of cylinder.
WARNING
After installation, test for proper operation. 10. Apply a thin layer of #2 multipurpose grease with
STAY CLEAR OF THE STEERING WHEEL 2 to 4% molybdenum disulfide to the inside of the
WHEN INITIALLY ENERGIZING THE STEER- cylinder.
ING SYSTEM AFTER ASSEMBLY. If the control
unit and/or the hoses were not assembled cor- 11. Apply a light film of hydraulic oil on cylinder and
rectly, the steering wheel can rotate with a O-ring. Install O-ring into gear housing on top of
strong force. If this action occurs, disassem- liners. Screw cylinder into end of gear housing.
ble the control unit and correct the existing
12. Operate unit several times. Install plug screw
problem.
into gear housing.
NOTE: Use new seals and O-rings during assembly.
13. Connect battery connector. Remove blocks from
Lubricate all parts with clean hydraulic oil.
between tires and steer axle.
1. Install shaft seal and bearing raceway into bot-
14. Install rear compartment cover. Lower lift truck
tom of gear housing. See Figure 12.
to floor and remove blocks from drive wheels.
2. Install safety ring in groove at top of gear hous- Test operate lift truck before returning lift truck
ing. Install shaft seal into top of gear housing. to service.
17
Troubleshooting
The axle does not turn when The steering pump fuse is open. Check the steering pump fuse and re-
the steering wheel is turned. place if open.
The hydraulic oil level is low or there Check for leaks. Fill the hydraulic oil
is no oil in the tank. to the correct level.
No oil flow from the steering control Remove, clean, and install the steer-
unit to the rotary actuator. ing control unit, hoses, and rotary ac-
tuator.
The sleeve and spool in the steering Clean or repair steering control unit.
control unit will not move.
Hydraulic hoses damaged or connec- Check for leaks. Tighten hose con-
tions are open. nections; if leaks continue, replace
hoses.
The steering control unit may be Repair or replace steering control

damaged. unit.
The electric motor for the steering Repair or replace electric steering
pump needs repair. 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 Inspect the fuse; replace if open.
the steering system.
Suction inlet strainer may be Clean strainer.

clogged.
The axle rotates in the wrong The hydraulic hoses are connected Reconnect hydraulic hoses correctly.
direction from the direction incorrectly at the rotary actuator.
of the steering wheel.
The hydraulic hoses are connected Reconnect hydraulic hoses correctly.

incorrectly at the steering control
unit.
If the steering control unit was disas- Disassemble steering control unit
sembled, check the rotor for correct and align rotor correctly.
alignment.
18
The axle continues to turn A centering spring is broken in the Repair or replace steering control
after the steering wheel has steering control unit. unit.
stopped turning.
There is damage to the sleeve or the Repair or replace steering control

spool of the steering control unit. unit.
Check for dirt in the hydraulic sys- Drain hydraulic oil completely and
tem and the steering control unit. replace with new hydraulic oil and a
new hydraulic oil filter.
The power steering pump There is air entering the power steer- Check for air entering the pump
makes noise that is not nor- ing pump. through the inlet port or the seals
mal. between the pump and the motor.
The bearings in the electric motor Replace bearings in steering pump

or the power steering pump need motor.
repair.
Dirty inlet strainer. Clean inlet strainer using an

oil-based solvent.
Slow or difficult steering. The hydraulic oil level is low, or there Refill hydraulic oil in tank.
is no oil in the tank.
No oil flow from the steering control Remove, clean, and install the steer-
unit to the rotary actuator. ing control unit, hoses, and rotary ac-
tuator.
Steering gearbox seals leaking. Replace seals.
The sleeve and spool in the steering Clean or replace steering control
control unit are binding. unit.
Low hydraulic oil pressure. Check pump for correct operation.
The steering control unit damaged. Repair or replace the steering control
unit.
On-demand module defective. Replace module.
19
NOTES
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20

BRAKE SYSTEM
J1.6-2.0XMT (J30-40ZT) [J160]
PART NO. 1554629 1800 SRM 1076

SAFETY PRECAUTIONS

nance section.
manual:
WARNING
CAUTION
Brake System Table of Contents
TABLE OF CONTENTS
Introduction........................................................................................................................................................ 1
General ........................................................................................................................................................... 1
Brake Pedal Assembly ....................................................................................................................................... 3
Remove ........................................................................................................................................................... 3
Disassemble ................................................................................................................................................... 4
Assemble ........................................................................................................................................................ 4
Install ............................................................................................................................................................. 4
Master Cylinder ................................................................................................................................................. 4
Remove ........................................................................................................................................................... 4
Install ............................................................................................................................................................. 5
Adjustments ................................................................................................................................................... 6
Bleed the Brake System............................................................................................................................ 6
Adjust Linkage .......................................................................................................................................... 6
Brake Lines ........................................................................................................................................................ 6
Parking Brake .................................................................................................................................................... 7
Remove ........................................................................................................................................................... 7
Disassemble ................................................................................................................................................... 7
Assemble ........................................................................................................................................................ 9
Install ............................................................................................................................................................. 9
J1.6-2.0XMT (J30-40ZT) [J160]

"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
Introduction
GENERAL the need for repairs to your supervisor imme-
diately. If repair is necessary, attach a DO NOT
This section contains the description and repair OPERATE tag on the steering wheel. Remove
procedures for the brake system. Components the key from the key switch.
covered are the brake pedal assembly, the spring-ap-
plied/electrically-released parking brakes, and the
master cylinder system. Some parts associated with WARNING
the brake system are not covered in this section Disconnect the battery before opening the
because they are more closely associated with other drive unit compartment cover or inspecting or
systems. See the following list for information not repairing the electrical system. If a tool causes
included in this section: a short circuit, the high current flow from the
See the section Electrical System 2200 SRM battery can cause personal injury or property
1078 for information on brake lights and parking damage.
brake wiring.
WARNING
See the section Transaxle 630 SRM 1074 for in-
formation on the internal, wet brake system.
Throughout this section, forward will refer to travel battery until the procedure tells you to do so.
in the direction of the forks and left and right deter- Never have any metal on your fingers, arms,
mined by an operator sitting in the seat facing for- or neck. Metal items can accidentally make an
ward. See Figure 1. electrical connection and cause injury.
WARNING
Before performing any tests or adjustments,
block the lift truck to prevent unexpected
movement.
WARNING
been disconnected.
A. LEFT SIDE
B. RIGHT SIDE
C. FORWARD TRAVEL WARNING
Figure 1. Truck Orientation minals with a screwdriver or jumper wire.

CAUTION
To avoid controller damage, always disconnect
WARNING the battery, discharge the capacitor(s), and
Do not make repairs or adjustments unless you never put power to the controller while any
have both authorization and training. Repairs power wires are disconnected. Never short
and adjustments that are not correct can cre- any controller terminal or motor terminal to
erate a lift truck that needs repairs. Report
1
the battery. Make sure to use proper proce- 4. On the premium controller, also connect the 200-
dure when servicing the controller. ohm, 2-watt resistor across the controller’s P+
and B terminals for 10 seconds using insulated
1. Turn key switch to OFF position and disconnect jumper wires. See Figure 3.
the battery. Block load wheels to prevent lift
truck from moving. 5. Remove the 200-ohm, 2-watt resistor before re-
2. Remove two screws securing the electrical com-
partment and pull the compartment door open on
its hinges.




(Optional)


(Standard)
2
1800 SRM 1076 Brake Pedal Assembly
Brake Pedal Assembly

REMOVE 1. Turn the key switch to the OFF position and dis-
connect the battery.
It is not always necessary to remove the brake pedal
assembly to disassemble certain components. Parts 2. Remove floor mat and floor covers.
of the brake pedal assembly may be removed without
removing the assembly from the lift truck. The en- 3. Tag and disconnect brake switch wires and the
tire removal procedure is outlined below. Evaluate brake fluid sensor wiring harness.
the required service to determine if the entire brake
assembly should be removed. Perform only the steps
necessary to complete the required service. For the
following procedures, refer to Figure 4.
1. BRACKET 11. LOCKWASHER

2. PEDAL 12. CAPSCREW
3. BUSHING 13. SCREW
4. WASHER 14. NUTPLATE
5. BOLT 15. SPRING
6. NUT 16. MASTER CYLINDER
7. INSULATOR 17. SOCKET-HEAD CAPSCREWS
8. BRAKE SWITCH 18. CLEVIS PIN
9. PEDAL STOP 19. JAM NUT
10. WASHER 20. CLEVIS
Figure 4. Brake Pedal Assembly
3
Master Cylinder 1800 SRM 1076
4. Disconnect the brake supply line from the elbow b. Position pedal into bracket and align holes.
fitting on top of the master cylinder.
c. Install bolt through bracket and pedal and
5. Remove four capscrews and lockwashers secur- secure with bolt (5), washer (4), and nut (6).
ing bracket to frame.
d. Install master cylinder linkage to pedal us-
6. Lift brake pedal assembly from the lift truck. ing clevis pin and secure using cotter pin.
DISASSEMBLE e. Install pedal return spring.

CAUTION
1. Remove brake switch and insulator from bracket Do not overtighten switch. Overtightening can
by removing two screws (13) and nutplate if nec- damage plastic casing.
essary.
3. Install brake switch and insulator to bracket us-
2. Remove capscrews (12), lockwashers (11), and ing two screws (13) and nutplate. Adjust switch
washers (10) securing stops to bracket if neces- as necessary.
sary.
4. Install stops to bracket using capscrews (12),
3. Remove master cylinder if necessary. See Mas- lockwashers (11), and washers (10).
ter Cylinder, Remove in this section.
INSTALL
4. Remove brake pedal:
1. Place brake pedal assembly in position and align
a. Remove pedal return spring. the mounting holes.
b. Pull the cotter pin and remove clevis pin from 2. Install four capscrews and lockwashers securing
master cylinder if not already removed. bracket to frame.
c. Remove nut (6) and washer (4), and then 3. Connect brake switch wires and the brake fluid
slide bolt (5) from assembly. sensor wiring harness as removed.
d. Lift pedal from assembly. 4. Connect the brake supply line to the elbow fitting
on top of the master cylinder.
e. Remove bushing from pedal if necessary.
5. Bleed air from the brake system. See Master
ASSEMBLE Cylinder, Bleed the Brake System in this sec-
tion.
1. Install master cylinder if removed. See Master
Cylinder, Remove in this section. 6. Connect the battery and test for proper opera-
tion.
2. Install brake pedal:
7. Install the floor covers and the floor mat.
a. Install new bushing into pedal if removed.
Master Cylinder
REMOVE 4. Pull the cotter pin from the clevis pin and remove
the clevis pin connecting the master cylinder to
1. Turn the key switch to the OFF position and dis- the brake pedal.
connect the batteries.
5. Remove two socket-head capscrews, washers,
2. Remove the floor mat and floor plates. lockwashers, and nuts securing master cylinder
to bracket.
3. Disconnect the brake supply line from the elbow
fitting on top of the master cylinder.
4
1800 SRM 1076 Master Cylinder
6. Remove master cylinder from bracket. See Fig- 2. Install two socket-head capscrews, washers,
ure 5. lockwashers, and nuts securing master cylinder
to bracket.
INSTALL
3. Install the brake supply line to the elbow fitting
on top of the master cylinder.
CAUTION
The brake system uses the same type hydraulic 4. Attach the master cylinder to the brake pedal us-
oil as used in the hydraulic system. Use of auto- ing the clevis pin and a cotter pin. Adjust linkage
motive or other unapproved fluids can damage if necessary. See Adjustments, Adjust Linkage.
the brake system.
5. Bleed air from the brake system. See Adjust-
1. Position master cylinder to bracket and align ments, Bleed the Brake System.
mounting holes.
1. ELBOW FITTING 10. CLEVIS PIN

2. O-RING FITTING 11. COTTER KEY
3. SPRING 12. WASHER
4. VALVE ROD 13. JAM NUT
5. STOP PIN 14. PUSH ROD
6. O-RING AND GASKET 15. RUBBER BOOT
7. CYLINDER HOUSING 16. FILTER
8. STOP PLATE 17. RESERVOIR
9. CLEVIS 18. INDICATOR ASSEMBLY
Figure 5. Master Cylinder
5
Brake Lines 1800 SRM 1076
ADJUSTMENTS 3. When back pressure seems to be at the maxi-

mum, the technician must press and hold the
Bleed the Brake System pedal as far as it will go.
4. The second technician must slowly loosen the

CAUTION bleed valve on one of the transaxle housings
The brake system uses the same type hydraulic between the wheel and the frame. Air and hy-
oil as used in the hydraulic system. Use of auto- draulic oil should bubble from the valve until the
motive or other unapproved fluids can damage pedal is pressed to its mechanical travel limit.
the brake system.
5. The pedal should be held in this position while
When the brake system is operating properly, the the valve is retightened.
brake pedal will have back pressure that will stop
the pedal before it can be pressed to the end of its 6. Repeat Step 2 through Step 5 until hydraulic oil
mechanical travel limit. A brake system that has with no air (bubbles) flows from the valve. Check
air present may have some back pressure but not the hydraulic oil level in the master cylinder ev-
enough to stop the pedal before reaching its mechan- ery cycle and fill reservoir as necessary.
ical travel limit. The pedal may feel soft and incon-
sistent (spongy) and must be bled before operating 7. Perform Step 2 through Step 5 on the other
the lift truck. transaxle until all air has been bled from the
system.
NOTE: Bleeding air from the brake system requires
two technicians. One technician must sit in the Adjust Linkage
seat and operate the brake pedal while the other
To adjust the master cylinder linkage:
opens and closes the brake bleed valve located on
the transaxle housing. 1. Loosen the jam nut on the plunger shaft.
To bleed air from the brake system: 2. Remove the cotter pin from the clevis pin and
remove the clevis pin.
1. Remove the floor plates and check that the mas-
ter cylinder reservoir is full of hydraulic oil. 3. Turn the plunger shaft until the hole in the clevis
aligns with the mounting hole in the brake pedal.
2. One technician must sit in the seat and repeat-
edly press and release (pump) the brake pedal to 4. Install the clevis pin through the clevis and
increase the back pressure. The brake pedal may mounting hole in the brake pedal. Secure with
become harder to press as this occurs. cotter pin.
Brake Lines
are metal tubes filled with hydraulic oil connected by
WARNING hydraulic fittings. Brake lines run below the floor
Do not try to find hydraulic leaks by putting plates, from the master cylinder to a tee fitting lo-
hands on pressurized components. Hydraulic cated near the front of the frame. They continue from
oil can be injected into the body, resulting in there as separate left hand (LH) and right hand (RH)
serious injury. lines through the frame to a fitting on each transaxle.
The drive wheel may be removed to access this con-
Hydraulic pressure is transferred from the master
nection. See Figure 6.
cylinder to the transaxles through brake lines. These
6
1800 SRM 1076 Parking Brake
Legend for Figure 6

1. MAIN LINE 4. TEE FITTING
2. RH LINE 5. FITTING
3. LH LINE 6. TRANSAXLE
Figure 6. Brake Lines
Parking Brake
The parking brake consists of two identical 4. Disconnect the parking brake wiring harness
spring-applied/electrically-released brakes mounted near the parking brake assembly.
directly to the drive motors. The controller breaks
the power supply to the brake coils, engaging the 5. Remove the four capscrews (9), lockwashers (10),
parking brake when the truck is stopped. Pressing and washers (11) securing the brake assembly to
the emergency disconnect will apply the parking the drive motor.
brake immediately in any mode of operation. The
6. Slide brake assembly from the motor shaft.
parking brakes may be released for towing by con-
necting the two brake release connectors located
DISASSEMBLE
near the right front fender beside the brake diode
assembly on the wiring harness. Connecting the 1. Remove the parking brake from the drive motor.
connectors energizes the brake coil, releasing the See Remove. Place on a clean workbench with
friction disk. The following procedures detail the the mounting plate facing up.
removal, disassembly, assembly, and installation
procedures for the parking brakes. Refer to Fig- 2. Remove three countersunk, socket-head screws
ure 7. from the mounting plate of the brake assembly.
REMOVE
CAUTION
1. Raise and safety chain the mast to prevent unex- Be sure to collect all of the spacers. Make a note
pected movement while working under the mast. of orientation for proper assembly.
See the section Periodic Maintenance 8000
SRM 1079 for instructions on properly safety 3. Lift mounting plate from brake assembly and col-
chaining the mast. lect spacers.
2. Turn key switch to the OFF position and discon- 4. Remove friction disc. Inspect disc for wear. Re-
nect the battery. place if necessary.
3. Block the wheels of the truck to prevent unex- 5. Inspect mounting plate and pressure plate for ex-
pected movement. cessive wear. Replace if necessary.
7
Parking Brake 1800 SRM 1076
1. BRAKE COIL 7. MOUNTING PLATE

2. SPRINGS 8. COUNTERSUNK SCREWS
3. PRESSURE PLATE 9. CAPSCREWS
4. SPACERS 10. LOCKWASHERS
5. SHIMS 11. WASHERS
6. FRICTION DISK 12. WIRING HARNESS
Figure 7. Parking Brake
NOTE: If only replacing the friction disc and/or 7. Remove and inspect the springs from the brake
mounting plate, no more disassembly is required. coil. Replace ALL springs if any show damage.
6. Remove the pressure plate from the assembly. 8. Replace brake coil if necessary.
Collect the three spacers.
8
ASSEMBLE INSTALL
1. Place brake coil on a clean workbench with the 1. Position the brake assembly onto the drive mo-
spring holes facing up. tor shaft and secure to the motor housing using
four capscrews (9), lockwashers (10), and wash-
2. Install springs into the spring holes in brake coil. ers (11).
3. Position pressure plate on top of the springs and 2. Install brake wiring harness.
align holes with the brake coil mounting holes.
3. Remove safety chains from the mast. See the sec-
4. Install new friction disk onto pressure plate with tion Periodic Maintenance 8000 SRM 1079 for
splined hub side down. instructions on properly removing safety chains
from the mast.
5. Install spacers into pressure plate and position
shims on top of spacers as removed. 4. Remove blocks from the wheels.
6. Carefully position mounting plate on top of as- 5. Connect the battery. Sit in the seat and turn key
sembly with mounting holes aligned as not to dis- switch to the ON position. Listen for the parking
turb the shims. brakes to release. Check for proper operation.
7. Install three countersunk mounting screws
through mounting plate, shims, spacers, and
pressure plate into the brake coil.
Troubleshooting
Brake pedal is hard to push. The linkage for the brake pedal Adjust or replace linkage.
needs adjustment.
Internal transaxle damage. Troubleshoot the transaxles.
Brake pedal travels too far. Air is in the brake system. Bleed air from system.
The linkage for the brake pedal is Adjust or replace linkage.

wrong.
The brake system has a leak. Tighten connections and monitor

closely.
Brakes make too much noise. Internal transaxle damage. Troubleshoot the transaxles.
Service brakes do not oper- A brake line has a restriction. Clean out brake line.
ate equally.
Parking brake is dragging. Adjust or repair park brake.
9
Service brakes do not re- Damage to system from incorrect Remove and clean entire system,
lease. brake fluid. then repair damage.
Parking brake is not releasing. Troubleshoot parking brake.
Parking brake will not re- Key switch is in the OFF position. Turn key switch to the ON position.
lease.
Battery is not connected or is dis- Connect or clean battery connections.

charged. Charge if necessary.
Wiring or controller malfunction(s). Refer to wiring diagrams.
Excessive wear. Adjust air gap between brake coil and

pressure plate to 0.30 to 0.46 mm
(0.012 to 0.018 in.) by adjusting
shims or replacing worn components.
Brake coil is defective. Check brake coil resistance. Resis-

tance should read 32.5 ohms ±10%.
Replace brake assembly or coil if nec-
essary.
Parking brake will not apply. Brake override connector is in place. Disconnect override connector and
connect to brake connector.
Air gap is too large. Replace the brake assembly.
Internal mechanical damage to Repair or replace the brake assembly.

brake.
Parking brake does not hold Oil or grease on the friction surfaces. Clean the brake assembly.
truck loaded to specification.
Friction surfaces are worn out. Repair the brake assembly.
Springs are too weak. Repair the brake assembly.
10

HYDRAULIC SYSTEM
J1.6-2.0XMT (J30-40ZT) [J160]
PART NO. 1554630 1900 SRM 1077

SAFETY PRECAUTIONS

trucks.
nance section.
manual:
WARNING
CAUTION
Hydraulic System Table of Contents
TABLE OF CONTENTS
Introduction........................................................................................................................................................ 1
General ........................................................................................................................................................... 1
Hydraulic System............................................................................................................................................... 3
Hydraulic Oil ................................................................................................................................................. 3
Hydraulic Lines ............................................................................................................................................. 3
Cleaning ......................................................................................................................................................... 3
Sound Level.................................................................................................................................................... 3
Maintenance .................................................................................................................................................. 3
Hydraulic Oil Filter, Change .................................................................................................................... 3
Hydraulic Oil Strainer, Check .................................................................................................................. 4
Hydraulic Oil, Change .............................................................................................................................. 4
Hydraulic Tank Assembly ................................................................................................................................. 6
Remove ........................................................................................................................................................... 6
Clean .............................................................................................................................................................. 7
Trisodium Phosphate Method................................................................................................................... 7
Install ............................................................................................................................................................. 7
Lift Pump and Motor ......................................................................................................................................... 8
Remove ........................................................................................................................................................... 8
Disassemble ................................................................................................................................................... 8
Assemble ........................................................................................................................................................ 8
Install ............................................................................................................................................................. 9
Lift Pump............................................................................................................................................................ 10
Disassemble ................................................................................................................................................... 10
Assemble ........................................................................................................................................................ 10
J1.6-2.0XMT (J30-40ZT) [J160]

"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
Introduction
GENERAL
This section contains the description and repair pro-
cedures for the hydraulic system. Components cov-
ered include the hydraulic tank, lift pump, filter as-
sembly, and hoses. Some parts associated with the
hydraulic system are not covered in this section be-
cause they are more closely associated with other sys-
tems. See the following list for information not in-
cluded in this section.
• See the section Electrical System 2200 SRM
1078 for information on the lift truck electrical
systems.
• See the section Steering System 1600 SRM 1075
for information on steering system components and
functions. A. LEFT SIDE
• See the section AC Motor Controllers/Display B. RIGHT SIDE
C. FORWARD TRAVEL
Panel, Description, Checks, Adjustments,
and Troubleshooting 2200 SRM 1087 for infor- Figure 1. Truck Orientation
mation on power delivery to the traction motor
(and lift pump motor on transistor hydraulic mod- DISCHARGING THE CAPACITORS
els).
• See the section Electro-Hydraulic Control
WARNING
Valve 2000 SRM 1086 for information on the elec-
tro-hydraulic control valve, valve controller, and Do not make repairs or adjustments unless you
hydraulic control switches. are properly trained and have been authorized
• See the section HUSCO™ Main Control Valve to do so. Repairs and adjustments that are not
2000 SRM 1085 for information on the manually correct can create dangerous operating condi-
controlled hydraulic valve. tions. Do not operate a lift truck that needs re-
• See the section Periodic Maintenance 8000 SRM pairs. Report the need for repairs to your su-
1079 for information on regularly scheduled main- pervisor immediately. If repair is necessary, at-
tenance procedures. tach a DO NOT OPERATE tag to the steering
• See the section Mast, Repairs 4000 SRM 522 for wheel and remove the key from the key switch.
information on lift cylinders and mast systems.
• See the section Capacities and Specifications WARNING
8000 SRM 1080 for proper torque values, fluid Disconnect the battery before opening the elec-
capacities, pressure settings, and other specifica- trical compartment cover and/or inspecting or
tions. repairing the electrical system. If a tool causes
• See the section Tilt Cylinders 2100 SRM 103 for a short circuit, the high current flow from the
information on tilt cylinders and tilt hydraulic sys- battery can cause personal injury or property
tems. damage.
Throughout this section, forward will refer to travel
in the direction of the forks and left and right deter- WARNING
mined by an operator sitting in the seat facing for- Some checks and adjustments are performed
ward. See Figure 1. with the battery connected. Do not connect
the battery until the procedure tells you to do
so. Never have any metallic objects, such as
jewelry, on your fingers, arms, or neck. Metal
items can accidentally make an electrical con-
nection and cause injury.
1
WARNING
Block the lift truck tires to prevent unexpected
movement before performing any tests or ad-
justments.
WARNING
The capacitor(s) in the transistor controller
been disconnected.
CAUTION
To avoid controller damage, always disconnect 1. POSITIVE CONNECTION (BT+)
the battery, discharge the capacitor(s), and 2. NEGATIVE CONNECTION (B )
never apply power to the controller while any 3. INSULATED JUMPER WIRES
power wires are disconnected. Never short 4. 200-OHM, 2-WATT RESISTOR
the battery. Make sure to follow proper proce- Figure 2. Discharging the Capacitors
dure when servicing the controller. (Standard)

the battery.
2. Block load wheels to prevent lift truck from mov-

ing.
WARNING
NOTE: Some lift trucks are equipped with a pre-

mium controller, which controls the hydraulic motor,
as well as the traction motors.

4. On the premium controller, also connect the 200- 1. POSITIVE CONNECTION (BT+)
ohm, 2-watt resistor across the controller’s P+ 3. INSULATED JUMPER WIRES
and B terminals for 10 seconds using insulated 4. 200-OHM, 2-WATT RESISTOR
jumper wires. See Figure 3. 5. POSITIVE CONNECTION (P+)
5. Remove the 200-ohm, 2-watt resistor before re- Figure 3. Discharging the Capacitors
connecting the battery. (Premium)
2
1900 SRM 1077 Hydraulic System
Hydraulic System
HYDRAULIC OIL • Cavitation - Can be caused by high fluid viscosity,
cold fluid temperatures, or a restriction in the in-
The hydraulic oil in the system performs the dual let screen or inlet tubing. At startup, low temper-
function of power transmission and lubrication. Us- atures can cause pump noises due to cavitation.
ing the proper oil is essential to system operation. • Aerated hydraulic oil - Results in system noise that
See the section Capacities and Specifications is similar to cavitation. Aerated oil is caused by
8000 SRM 1080 for the recommended hydraulic oil the ingestion of air through the joints of the in-
specifications and quantities. let lines and high-velocity discharge lines. Aera-
tion can also be caused by oil discharging above the
The hydraulic oil level should be checked first when
fluid level in the hydraulic reservoir. Aerated hy-
troubleshooting hydraulic system problems. Low oil
draulic oil occurs when air does not have sufficient
levels may cause it to appear that a problem exists
time to escape from the fluid while in the reservoir
with the battery or hydraulic components.
before recycling through the system.
HYDRAULIC LINES
MAINTENANCE
All hydraulic hoses and tubes must be thoroughly
cleaned before installation. Hydraulic Oil Filter, Change
When making repairs, use the least number of fit- Replace the filter element after the first 50 hours of
tings and connections to minimize flow resistance service and every 2000 hours or yearly thereafter.
and the possibility of leakage. See Figure 4.
1. Loosen the four capscrews (1) securing cover to

CLEANING
the hydraulic oil filter housing located on top of
Take precautionary measures to ensure that the hy- the hydraulic oil tank.
draulic system remains clean.
2. Press down on the cover while removing the cap-
1. Clean the reservoir and pump area before servic- screws to depress the element retainer spring.
ing to prevent contaminants from entering the
3. Remove the cover and spring from housing.
hydraulic system.
Check O-ring seal on the cover for cracks or
2. Clean (flush) the entire system when a failure is deterioration. Replace if damaged.
encountered to make sure all paint, metal chips,
4. Remove element from housing and replace with
welding shot, and debris are removed.
a new element.
3. Filter each change of oil to prevent the introduc-
5. Install the cover and spring to the housing using
tion of contaminants into the system.
four capscrews. Press the cover down onto the
4. Provide continuous protection from airborne con- housing while installing the capscrews. Torque
tamination by keeping the breather cap clean capscrews to 6 N•m (53 lbf in).
and serviceable.
6. Clean the breather cap/dipstick and check the oil
level. Add oil if necessary. See Figure 4.
SOUND LEVEL
Hydraulic system noise may be caused by both im-
properly selected oil and loose or damaged system
components.
3
Hydraulic System 1900 SRM 1077
6. Install the three screws and lockwashers (3) re-

taining the hydraulic oil strainer and gaskets to
the hydraulic tank.
7. Install the breather cap/dipstick.
Hydraulic Oil, Change
WARNING
The hydraulic oil is hot at normal operating
temperatures. Be careful when draining the
oil.
CAUTION
The hydraulic oil should be changed every 2000

1. CAPSCREW hours or yearly. Refer to Periodic Maintenance
2. BREATHER CAP/DIPSTICK 8000 SRM 1079 for hydraulic service intervals and
3. SCREW AND LOCKWASHER procedures. When the hydraulic system components
4. STRAINER ASSEMBLY such as the pump or steering control unit have been
5. CAPSCREW, LOCKWASHER, AND WASHER
6. STEERING RETURN damaged or the oil has otherwise been contaminated,
7. HYDRAULIC TANK the hydraulic system should be drained, repaired,
8. GROUND WIRE flushed, and refilled with new hydraulic oil.
Figure 4. Hydraulic Tank Assembly 1. Put the lift truck on a level surface and lower the
mast.
Hydraulic Oil Strainer, Check
2. Turn the key switch to the OFF position and dis-
Remove the breather cap/dipstick from the top of the connect the battery.
hydraulic tank. Visually inspect the hydraulic oil
strainer located inside the fill hole. The screen must
WARNING
be kept clean in order to strain the new oil added to
the system. If dirt, trash, rust, or sludge is present, Use one piece, solid hardwood blocks to sup-
clean the strainer. If the strainer cannot be cleaned port the lift truck. Make sure the lift truck is
or is broken, it should be replaced. See Figure 4. stable and secure before performing service.
1. Remove the breather cap/dipstick. 3. Position the lift truck on blocks approximately
305 mm (12 in.) off the floor. See Periodic
2. Remove the three screws and lockwashers (3) re- Maintenance 8000 SRM 1079, How to Put Lift
taining the strainer assembly to the hydraulic Truck on Blocks.
tank.
4. Remove the floormat and floor plates.
3. Remove the strainer assembly from the tank.
5. Remove the breather cap/dipstick to allow faster
4. Clean or replace the strainer. Check the gaskets draining.
for damage. Replace if necessary.
5. Install the housing and strainer assembly to the

tank.
4
1900 SRM 1077 Hydraulic System
NOTE: Three hydraulic hoses attach to the bottom of 7. Remove the hose clamp and drain plug from the
the hydraulic tank: the larger, lift pump supply hose, end of the drain hose to drain the hydraulic oil.
the steering supply hose and the drain hose. The
drain hose exits the tank furthest from the larger, 8. When the oil has drained, reinstall the drain plug
lift pump supply hose and is coiled up and attached into the hose and secure with hose clamp.
to the lift supply hose using a wire tie. See Figure 5.
9. Coil the drain hose and place it back inside the
6. Access the drain hose: access hole as removed. Secure to larger hy-
draulic supply hose using a new wire tie.
a. Reach under the bottom of the lift truck and
locate the access hole in the bottom of the lift 10. Fill the hydraulic tank to the proper level
truck frame. with new hydraulic oil. DO NOT overfill the
hydraulic tank. Refer to Capacities and Spec-
b. Reach into the hole and find the drain hose. ifications 8000 SRM 1080 proper hydraulic oil
Using wire cutters, clip the wire tie retain- quantities and specifications.
ing the drain hose to the larger pump supply
hose and pull it through the access hole. NOTE: Check the hydraulic oil level by wiping the
dipstick clean and install the breather cap/dipstick
c. Position the hose to drain into a container onto the tank. Remove again and check the oil level
suitable to collect the used hydraulic oil with on the dipstick.
a minimum capacity of 19 liter (5 gal).
12. Connect the battery connector and turn the key

switch to the ON position.
13. Operate the lift pump for 1 to 2 minutes to purge

air from the hydraulic system, then recheck the
hydraulic oil level.
14. Install the floormat and floor plates.
15. Lower the lift truck from blocks. See Periodic

Maintenance 8000 SRM 1079, How to Put Lift
Truck on Blocks.
16. Test for proper operation before returning to ser-

vice.
1. HYDRAULIC TANK
2. LIFT PUMP SUPPLY HOSE
3. STEERING SUPPLY HOSE
4. DRAIN HOSE
Figure 5. Hydraulic Tank Hoses
5
Hydraulic Tank Assembly 1900 SRM 1077
Hydraulic Tank Assembly

REMOVE 9. Tag and disconnect the steering return hose, the
tank return hose, and ground wire from the top
1. Lower the forks completely and tilt the mast com- of the tank. See Figure 6.
pletely forward.
Tag and disconnect the steering supply hose from the
2. Turn the key switch to the OFF position and dis- steering pump and the lift pump supply hose from
connect the battery. Block the drive tires to pre- the bottom of the lift pump through the access hole
vent unexpected movement. in the battery compartment. See Figure 5.
3. Remove the battery from the lift truck to improve 10. Attach a sling and an overhead lifting device to
access to the lift pump. the tank. Tighten the lifting device to support
the weight of the tank.
4. Remove the floormat and the floor plates.
11. Remove the hydraulic tank from the lift truck.
WARNING
12. Remove hoses from the bottom of the tank if nec-
Use one piece, solid hardwood blocks to sup- essary.
port the lift truck. Make sure the lift truck is
stable and secure before perfoming service.
5. Position the lift truck on blocks approximately

305 mm (12 in.) off the floor. See Periodic
Maintenance 8000 SRM 1079, How to Put Lift
Truck on Blocks.
WARNING
Hydraulic oil is hot at normal operating tem-
peratures.
CAUTION
NOTE: Position a drip pan under the lift truck to

catch hydraulic oil spilled during the removal proce-
dures.
6. Drain the hydraulic oil from the tank. Refer to 1. CAPSCREW

2. BREATHER CAP/DIPSTICK
Hydraulic Oil, Change, in this section. 3. SCREW AND LOCKWASHER
4. STRAINER ASSEMBLY
7. Remove the hydraulic valve cover (manual valve 5. CAPSCREW, LOCKWASHER, AND WASHER
only). 6. STEERING RETURN
7. HYDRAULIC TANK
8. Remove the accelerator/brake pedal assembly 8. GROUND WIRE
from the lift truck. Remove the brake line be-
tween the master cylinder and the tee fitting. Figure 6. Hydraulic Tank Assembly
Cap the fittings on the master cylinder and the
tee fitting to prevent contamination.
6
1900 SRM 1077 Hydraulic Tank Assembly
CLEAN 4. Connect the steering return hose, the tank re-

turn hose, and ground wire to the top of the tank.
When cleaning the tank, do not use solutions that See Figure 6.
produce dangerous gases at normal temperatures or
when heated. Wear eye and face protection and pro- 5. Install the accelerator/brake pedal assembly to
tective clothing to prevent burns. the lift truck. Remove caps and install the brake
line between the master cylinder and the tee fit-
When cleaning with pressurized water, use a hose ting. Bleed air from the brake system.
with a minimum diameter of 19 mm (0.75 in.). Con-
trol the pressure of the water using a valve installed 6. Fill the hydraulic tank to the proper level with
at the nozzle of the hose. If a metal nozzle is used, hydraulic oil. Check the oil level using the
it must be made of a non-sparking material. Main- breather cap/dipstick. DO NOT OVERFILL.
tain an electrical connection between the nozzle and Install the breather cap/dipstick to the tank.
tank. Connect a ground wire to the tank to prevent
buildup of static electricity. NOTE: Check the hydraulic oil level by wiping the
dipstick clean and installing the breather cap/dip-
Trisodium Phosphate Method stick onto the tank. Remove again and check the oil
level on the dipstick.
If the tank cannot be cleaned with pressurized water,
use the following procedure: 7. Remove the drip tray from under the truck. Dis-
pose of waste oils properly.
1. Mix a solution of water and trisodium phosphate
or a cleaning compound with an alkali base. Al- 8. Purge air from the hydraulic system and check
ways follow the cleaner manufacturer’s recom- for leaks.
mendations.
a. Install the battery to the lift truck.
2. Fill the tank with cleaning solution. Use com-
b. Connect the battery. Turn the key switch to
pressed air to mix the solution in the tank.
the ON position while seated in the seat.
3. Drain the tank.
c. Raise and lower the mast several times.
4. Flush the inside of tank with hot (boiling) water. Then completely lower the mast and tilt
Make sure all cleaning compound and all loose forward until the forks touch the ground.
material is removed from inside of tank.
d. Turn the key switch to the OFF position and
5. Inspect the inside of tank using a light approved disconnect the battery.
for locations with flammable vapors.
e. Check for leaks around hose connections.
6. If the tank is not clean, repeat Step 1 through
f. Check the oil level using the breather cap/
Step 4 until tank is clean.
dipstick. Add hydraulic oil to the proper level
INSTALL if necessary.
1. Install hoses to the bottom of the tank, if re- 9. Install hydraulic valve cover (manual valve
moved. only).
2. Attach a sling and an overhead lifting device to 10. Install floor plates and floormat.
the tank. Position the tank into the lift truck. 11. Remove blocks from the drive tires, connect the
3. Install the steering supply hose to the steering battery, and test for proper operation before re-
pump and, install the lift pump supply hose to turning lift truck to service.
the lift pump inlet.
7
Lift Pump and Motor 1900 SRM 1077
Lift Pump and Motor

REMOVE 7. Drain the hydraulic oil from the tank. See Hy-
draulic Oil, Change, in this section.
8. Tag and disconnect all electrical wires and hy-
1. Lower the forks completely and tilt the mast com- draulic hoses from the lift pump and motor as-
pletely forward. sembly.
9. Attach a sling and an overhead lifting device to

the lift pump and motor assembly. Tighten the
lifting device just enough to support the weight of
the assembly while removing the attaching hard-
ware.
10. Remove the top capscrew and washers retaining

the mounting plate of the lift pump and motor
assembly to the to the lift truck frame.
11. Lift the assembly off the lower spacer stud as-
semblies and from the truck using the overhead
lifting device.
12. Remove the lower spacer stud assemblies from

the frame if necessary.
DISASSEMBLE
1. Remove the capscrews and washers retaining the
1. LIFT PUMP MOTOR mounting bracket to the lift pump and motor as-
2. FRAME
3. TOP CAPSCREW sembly. See Figure 8.
4. LOWER SPACER STUD ASSEMBLIES
5. DRAIN HOSE 2. Remove the socket-head screws securing lift
6. LIFT PUMP SUPPLY HOSE pump to motor. See Figure 9.
7. HOSE CLAMP
8. LIFT PUMP 3. Separate lift pump from motor.
9. HYDRAULIC TANK
10. MOUNTING PLATE ASSEMBLE
Figure 7. Lift Pump, Motor Assembly, and 1. Slide pump onto motor shaft and align holes in
Hydraulic Tank both housings.
2. Turn the key switch to the OFF position and dis- 2. Install socket-head capscrews securing lift pump
connect the battery. Block the drive tires to pre- to motor. Torque to 61 N•m (45 lbf ft). See Fig-
vent unexpected movement. ure 9.
3. Remove the battery from the lift truck to allow 3. Check the conditions of the isolator bushings.
access to the lift pump hydraulic lines. Replace if necessary.
4. Remove the cover from the control valve. 4. Position the mounting bracket to the lift pump
and motor assembly and install the capscrews
5. Remove the floormat and the floor plates.
and washers retaining the mounting bracket to
6. Position a drip pan under the lift truck to catch the lift pump and motor assembly. See Figure 8.
hydraulic oil spilled during the removal proce-
dures.
8
1900 SRM 1077 Lift Pump and Motor
Legend for Figure 9

1. LIFT PUMP
2. SOCKET-HEAD SCREWS
3. LIFT PUMP MOTOR
INSTALL
1. Install the lower spacer stud assemblies to the

frame if removed. Torque to 48 N•m (35 lbf ft).
2. Position the lift pump and motor assembly into

the truck using the overhead lifting device. Slide
the mounting plate slots onto the lower spacer
studs.
3. Install top capscrew, washers, and nut securing

mounting plate to frame. Torque to 48 N•m
(35 lbf ft). Remove sling and lifting device.
1. LIFT PUMP AND MOTOR ASSEMBLY
2. NUT 4. Connect electrical wiring and hydraulic hoses to
3. LOCKWASHER
4. WASHER the assembly as removed.
5. FRAME
6. WASHER 5. Fill the hydraulic tank to the proper level with
7. TOP CAPSCREW hydraulic oil. Check the oil level using the
8. LOWER SPACER STUD ASSEMBLIES breather cap/dipstick. DO NOT OVERFILL.
9. LOWER CAPSCREWS
10. LOCKWASHER 6. Purge air from the hydraulic system and check
11. WASHER for leaks:
12. SPACER
13. NUTPLATE a. Install the battery into the lift truck.
14. MOUNTING BRACKET
15. ISOLATOR BUSHINGS
16. WASHER b. Connect the battery. Turn the key switch to
17. LOCKWASHER the ON position while sitting in the seat.
18. CAPSCREWS
c. Raise and lower the mast several times.
Figure 8. Mounting Bracket Then completely lower the mast and tilt
forward until the forks touch the ground.
d. Turn the key switch to the OFF position and

e. Visually inspect the hydraulic system for

leaks.
f. Check the oil level again and fill to the proper

level, if necessary.
7. Remove the drip tray from under the truck. Dis-

pose of waste oils properly.
Figure 9. Lift Pump and Motor Assembly
9
Lift Pump 1900 SRM 1077
8. Install floor plates and floormat. 10. Remove blocks from the drive tires, connect the
battery, and test for proper operation before re-
9. Install cover to the hydraulic valve. turning to service.
Lift Pump
DISASSEMBLE 7. Remove the snap ring from the mounting flange.
Drive the oil seal from the flange using a hammer
The lift pump must be removed from the lift truck and a punch. See Figure 10.
to disassemble. Check each component for signs of
wear. See Lift Pump and Motor for removal instruc- ASSEMBLE
tions. Place the pump on a clean workbench for dis-
assembly. Refer to Figure 10. Thoroughly clean parts to be reused and assemble in
a clean environment.
1. Remove the lift pump and motor assembly from
the lift truck and remove the lift pump from the
motor. See Lift Pump and Motor.
CAUTION
Be careful not to damage the flange when in-
NOTE: Make note of the orientation of the hydraulic stalling the oil seal.
fittings to assist during assembly.
1. Using a press, install the oil seal (13) into the
2. Remove hydraulic fittings from pump assembly mounting flange (2). Install the snap ring (14).
if necessary.
2. Install the gears (7, 8) to the pump housing.
3. Remove capscrews securing the cover and the
mounting flange to the pump housing. Remove 3. Install the seals (10) and rings (11) into the bush-
the cover and mounting flange and collect the ings. Install the bushings (5, 6) to each end of the
seals (9). pump housing onto the gear shafts.
4. Remove the bushings (5, 6) from each end of the 4. Install the seals (9) and position the cover and
pump housing. Remove seals (10) and rings (11) mounting flange to the pump housing.
from the bushings.
5. Install four capscrews securing pump assembly
5. Remove the gears (7, 8) from the pump housing. together and torque to 58 N•m (43 lbf ft).
6. Inspect the bushings, gears, and the inside of the 6. Install hydraulic fitting to the pump assembly, if
pump housing for wear. Any component with no- removed. Check O-rings for damage and replace
ticeable wear must be replaced. Check that the as necessary. Make certain that the hydraulic
gear shaft fits snugly in the bushings and is not fittings are oriented in the proper position for
worn. installation of the hydraulic lines. Tighten fit-
tings to compress O-rings and seal the connec-
tions. DO NOT torque beyond 80 N•m (59 lbf ft).
CAUTION
Be careful not to damage the flange when re-
moving the oil seal.
10
1900 SRM 1077 Lift Pump
1. SCREW 8. GEAR
2. MOUNTING FLANGE 9. SEAL
3. COVER 10. SEAL
4. PUMP HOUSING 11. RING
5. BUSHING 12. RING
6. BUSHING 13. OIL SEAL
7. GEAR 14. SNAP RING
Figure 10. Lift Pump Assembly
11
NOTES
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12

HUSCO™ MAIN
CONTROL VALVE
J1.60-2.00XMT (J30-40ZT) [J160]
PART NO. 1554631 2000 SRM 1085

SAFETY PRECAUTIONS

trucks.
nance section.
manual:
WARNING
CAUTION
HUSCO™ Main Control Valve Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Description ......................................................................................................................................................... 1
Operation............................................................................................................................................................ 1
Lift Section..................................................................................................................................................... 4
Tilt Section ..................................................................................................................................................... 4
Tilt Backward ............................................................................................................................................ 4
Tilt Forward............................................................................................................................................... 4
Relief Valve .................................................................................................................................................... 6
Main Control Valve Repair ................................................................................................................................ 7
Remove ........................................................................................................................................................... 7
Disassemble ................................................................................................................................................... 9
Assemble ........................................................................................................................................................ 9
Install ............................................................................................................................................................. 11
Pressure Relief Valve Check and Adjustment.................................................................................................. 14
Primary Relief Valve...................................................................................................................................... 14
Secondary Relief Valve .................................................................................................................................. 14
J1.60-2.00XMT (J30-40ZT) [J160]

"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
2000 SRM 1085 Operation
General
This section has a description and the repair procedures for the main control valve and the linkage arrange-
ment.
Description
The main control valve controls the operation of the Each function of the main control valve is made as a
lift, tilt, and auxiliary cylinders. The main control separate section having a spool and valve body. Each
valve is installed to the right of the operator, at the valve body casting is the same. The control spools are
level of the floor plate. The main control valve has different for each function. Other sections are added
the following sections (see Figure 1): to the main control valve to control optional auxiliary
• Inlet section with the primary relief valve functions.
• Lift and lower section
• Tilt section Each spool has a spring that returns the spool to the
• Auxiliary section(s) with the secondary relief valve neutral position when the control lever is released.
Each valve section has a check valve in the valve
The sections are held together with three through- body. The check valve and spring are held in the
bolts. valve body by the next section.
Operation
The main control valve is an open-center, parallel forward to lower the mast. Pull the lever back to lift
circuit valve. When open-center valve spools are in the mast. The second lever controls the tilt function.
the neutral position, the hydraulic oil flows through Move the lever forward to tilt the mast forward. Pull
the valve with minimum restriction. The oil returns the lever back to tilt the mast back. The optional
through the drain passage and returns to the hy- third control lever is for attachments and has two
draulic tank. Except during lifting, each spool can methods of operation depending on the attachment.
be operated without preventing the flow of oil to an- • Control Lever With Detent – Required for At-
other spool. tachments With a Clamp Action: The lever is
spring-loaded toward the operator. The lever is op-
This valve has three parallel passages through the erated by moving it to the right, then forward or
valve. See Figure 2. When the spools are in the backward.
neutral position, the oil flows through the open cen- • Control Lever Without a Detent – Attach-
ter passage. At the end of the valve, the oil returns ments Without a Clamp Action: The lever is
through the drain passage and returns to the hy- operated by moving forward or backward.
draulic tank. When a spool is moved from the neu-
tral position, it makes a restriction in the open-center The optional fourth control lever has a detent and
passage. This restriction causes an increase in pres- is spring-loaded toward the operator. The lever is
sure in the parallel passage. The parallel passage operated by moving it to the right, then forward or
is common to all sections of the valve, but oil can- backward.
not flow freely through it. The increased pressure in
the parallel passage causes the oil to flow through Each of the control levers actuate a mechanical
a check valve into a supply cavity in the valve body. switch for the hydraulic pump. Movement of the tilt
The spool gives a path from the supply cavity to the or auxiliary levers in either direction causes a switch
hydraulic cylinder to do work. to start the hydraulic pump. The lift/lower control
lever actuates its switch only in the lift position.
The first lever to the right of the operator controls
the lifting and lowering of the mast. Move the lever
1
Operation 2000 SRM 1085
1. INLET SECTION 5. TILT SPOOL

2. LIFT SECTION 6. AUXILIARY SPOOL
3. LIFT/LOWER SPOOL 7. AUXILIARY SECTION
4. TILT SECTION 8. TILT CONTROL SPOOL
Figure 1. Main Control Valve
2
A. UPPER PORT B. LOWER PORT

1. TILT CYLINDER 9. HYDRAULIC TANK
2. LOWERING CONTROL VALVE (EXTERNAL) 10. FILTER
3. LIFT CYLINDER 11. SECONDARY RELIEF VALVE
4. LOWERING CONTROL VALVE (INTERNAL) 12. TILT SPOOL
5. MAIN CONTROL VALVE 13. AUXILIARY SPOOL
6. LIFT/LOWER SPOOL 14. AUXILIARY SPOOL
7. PRIMARY RELIEF VALVE 15. SUPPLY PRESSURE TEST PORT
8. HYDRAULIC PUMP
Figure 2. Control Valve Schematic
3
LIFT SECTION Legend for Figure 3
When the spool is in the Lower position, the spool A. LOWER B. LIFT
opens a path from the lift cylinders to the drain cav-
1. LIFT/LOWER 5. OPEN CENTER
ity. See Figure 3. The spool is made so the open cen- SPOOL PASSAGE
ter passage has no restriction. 2. SUPPLY CAVITY 6. TO LIFT
3. TO/FROM LIFT CYLINDERS
When the spool is moved to the Lift position, the spool CYLINDERS 7. TO HYDRAULIC
makes a restriction in the open center passage. The 4. DRAIN CAVITY TANK
increased pressure in the parallel passage causes oil
to flow through the check valve to the supply cavity. TILT SECTION
The oil flows from the supply cavity through a section
The basic operation of the tilt spool is the same as
of the spool to the lift cylinders.
the other spools in this control valve. The tilt control
spool that is inside the tilt spool adds an additional
sequence to the tilt forward function.
Tilt Backward
When the spool is moved to the Back Tilt position, the
tilt spool causes a restriction of the oil flow through
the open center passage. See Figure 4. The increased
pressure in the parallel passage causes the oil to flow
through the check valve to the supply cavity. The oil
flows from the supply cavity through a section of the
spool to the rod side of the tilt cylinders. The check
valve prevents the movement of the load until the
system pressure is great enough to control the load.
Oil from the piston end of the tilt cylinders returns
through the main control valve to the hydraulic tank.
Tilt Forward
The tilt control spool that is inside of the tilt spool
operates during the Forward Tilt function. See Fig-
ure 4. The tilt control spool prevents cavitation in
the piston end of the tilt cylinders. Cavitation occurs
when the available fluid does not fill the space in a
closed system. The high vacuum causes some of the
fluid to change to bubbles of gas. When cavitation
occurs in the tilt cylinders, the tilt forward function
is not smooth.
The tilt control spool permits the regulation of the

tilt speed by using the pressure from the hydraulic
pump.
The pressure must be 550 kPa (80 psi) on the piston

end of the tilt cylinders. The tilt control spool pre-
vents oil flow from the rod end of the tilt cylinders
Figure 3. Lift and Lower Spools until the pressure is 550 kPa (80 psi). This action
makes sure that a vacuum cannot occur at the piston
end of the tilt cylinders.
4
A. TILT BACKWARD B. TILT FORWARD

1. OPEN CENTER PASSAGE 5. TILT SPOOL
2. SUPPLY CAVITY 6. TO/FROM ROD END OF TILT CYLINDERS
3. TO/FROM PISTON END OF TILT CYLINDERS 7. TILT CONTROL SPOOL
4. DRAIN CAVITY
Figure 4. Tilt Spool Operation
5
RELIEF VALVE one of the hydraulic circuits reaches the relief valve
setting, the relief valve opens a path between the
The relief valves control the maximum pressure inlet and drain circuits.
within a hydraulic circuit. The control valve has a
primary relief valve and a secondary relief valve. The relief valve is a poppet valve that is pilot op-
The primary relief valve is installed in the inlet erated. There are four poppet spools in this valve.
section of the control valve and is for the lift and tilt Spools C, D, and E are used for pressure relief. This
circuits. The secondary relief valve is for the auxil- relief valve gives almost constant relief pressure over
iary circuits and is installed in the outlet section of the range of the hydraulic pump flow. The sequence
the control valve. Both relief valves are the same of operation is described in Figure 5.
in description and operation. When the pressure in
1. STEP 1 - THE RELIEF VALVE IS CLOSED BETWEEN THE HIGH PRESSURE (HP) INLET AND THE LOW
PRESSURE (LP) DRAIN. HIGH PRESSURE OIL ENTERS THE PASSAGE AT C. THE DIFFERENCE IN
AREA BETWEEN DIAMETERS A AND B HOLDS THE POPPET SPOOL D AGAINST THE VALVE SEAT.
2. STEP 2 - THE OIL PRESSURE IN THE HIGH PRESSURE INLET BECOMES GREATER THAN THE SPRING
FORCE OF THE PILOT POPPET E. THE PILOT POPPET E IS PUSHED FROM ITS SEAT. OIL FLOWS
AROUND THE POPPET E AND THROUGH THE PASSAGES TO THE DRAIN.
3. STEP 3 - WHEN PILOT POPPET E OPENS, THE LOSS OF OIL PRESSURE BEHIND POPPET C CAUSES
POPPET C TO MOVE AGAINST POPPET E. THIS MOVEMENT STOPS THE FLOW OF OIL THROUGH C
AND CAUSES A LOWER PRESSURE BEHIND RELIEF VALVE POPPET D.
4. STEP 4 - THE DIFFERENCE IN PRESSURE ON EACH SIDE OF POPPET D CAUSES POPPET D TO OPEN.
THE HIGH PRESSURE OIL THEN HAS A DIRECT PATH TO THE LOW PRESSURE DRAIN.
Figure 5. Relief Valve Operation
6
2000 SRM 1085 Main Control Valve Repair
Main Control Valve Repair

REMOVE 6. Tag and disconnect the pressure and supply
line from the pump. This line can be accessed
The hydraulic control valve assembly is mounted to through the battery compartment.
a supporting bracket, which is secured to the frame
of the truck. To remove these parts, use the following 7. Tag and disconnect all remaining hydraulic hoses
procedures and see Figure 6. at the fittings. Drain any excess hydraulic oil
into a suitable container.
WARNING 8. Disconnect the hydraulic wiring harness connec-
Before making any repairs to the control valve, tor from the main wiring harness.
tilt the forks until they are parallel to the floor.
Lower the mast until the forks rest on the floor.
This action will prevent the mast from lower- WARNING
ing suddenly when the hydraulic lines are dis- The hydraulic control valve is heavy. Be sure
connected. that all lifting devices (hoists, cables, chains,
slings, etc.) are suitable and of adequate capac-
1. Fully lower the mast. ity to lift the hydraulic control valve. The hy-
draulic control valve can weigh 11.4 to 13.6 kg
2. Disconnect the battery. Remove the battery to (25 to 30 lb) without any attachments.
gain access to the mounting capscrews for the
hydraulic control valve. Follow the instructions 9. Support the hydraulic control valve assembly.
in Periodic Maintenance 8000 SRM 1079 for Remove the three capscrews (16), washers (17),
battery removal information. lockwashers (18), nuts (19), and brackets (15)
securing the top of the supporting bracket to the
3. Remove the battery spacer plates, if required. frame. Loosen the two capscrews (16), washers
(17), lockwashers (18), nuts (19), and brack-
WARNING ets (15) securing the bottom of the supporting
Hydraulic oil is hot at normal operating tem- bracket to the frame. Carefully lift the entire
perature. hydraulic control valve assembly and supporting
bracket out of the truck.
CAUTION 10. Move the hydraulic control valve assembly and

Disposal of lubricants and fluids must meet lo- supporting bracket to a clean workbench.
11. Remove the cotter pins (7), washers (28), if appli-
4. Operate the control valve levers in both direc- cable, and pins (8) connecting the lower linkage
tions to relieve any hydraulic pressure. to the hydraulic control valve.
5. Remove the screws (1) securing the lower cover. 12. Remove the three mounting capscrews (23),
Remove the cover. washers (24), lockwashers (25), and nuts (26)
securing the hydraulic control valve to the sup-
NOTE: Install plugs and caps to the hydraulic hoses porting bracket. Remove the hydraulic control
and fittings to prevent leaking and to prevent dirt valve from the supporting bracket.
from entering the system.
7
Main Control Valve Repair 2000 SRM 1085
Figure 6. Main Control Unit Mounting
8
Legend for Figure 6

1. SCREW 15. BRACKET
2. LOWER COVER 16. CAPSCREW
3. STANDOFF 17. WASHER
4. STANDOFF 18. LOCKWASHER
5. CAPSCREW 19. NUT
6. LINK 20. LOWER RUBBER CHANNEL
7. COTTER PIN 21. UPPER RUBBER CHANNEL
8. PIN 22. CONTROL VALVE
9. PIN 23. CAPSCREW
10. SNAP RING 24. WASHER
11. SPACER 25. LOCKWASHER
12. PIN 26. NUT
13. SPRING 27. SUPPORT BRACKET
14. STUD 28. WASHER
NOTE: Refer to Figure 7 for upper linkage and con- cleaning solvents, always follow the solvent
trol lever assembly. manufacturer’s recommended safety proce-
dures.
DISASSEMBLE
1. Clean only the parts of the control valve with
1. Clean the exterior of the hydraulic control valve. solvent. Do not get solvent in the electrical
switches.
NOTE: Disassemble the main control valve as nec-
essary for repairs. Most repairs to the main control 2. Check the spools and bores for wear or damage.
valve are for the replacement of O-rings and seals to If a spool or the bores have damage, the control
stop leaks. The passages in the tilt spool are small valve section must be replaced. Make sure the
and may need cleaning if the hydraulic oil becomes spools move freely in the bores.
dirty. The section normally must be replaced, if the
spool or valve section is damaged. 3. Check the check valves and relief valve(s) for
damage. Replace the parts as necessary.
2. Remove the end cap from the valve section. See
Figure 8. Carefully pull the spool from the valve 4. The relief valve is normally replaced as an as-
section. Do not remove the spring retainers, un- sembly if it is damaged.
less a spring must be replaced.
5. Check the parts of the linkage for the control
3. Tag and disconnect all electrical connections valve levers. Replace worn parts as necessary.
from the valve switches.
ASSEMBLE
4. The valve sections can be separated when the
three through-bolts are removed. The check CAUTION
valves are held in the valve body by the next
Before installing the parts into the valve body,
section.
make sure all parts are clean. Replace all the
5. Remove the tilt control spool by removing the end seals and the O-rings. Lubricate the moving
of the tilt spool. Carefully remove the tilt control parts with clean hydraulic oil during assembly.
spool from the tilt spool.
1. Install new seals in the bores of the sections. See
Figure 8. Install new O-ring seals between the
CLEAN AND INSPECT
sections. Install the check valves and springs
and assemble the sections. Tighten the nuts
WARNING on the small through-bolts to 10 N•m (7 lbf ft).
Cleaning solvents can be flammable and toxic Tighten the nuts on the large through-bolt to
and can cause skin irritation. When using 24 N•m (18 lbf ft).
9
Figure 7. Main Control Valve Upper Lever Mounting
10
Legend for Figure 7

1. UPPER COVER 20. WASHER
2. SCREW 21. CAPSCREW
3. LINKAGE FRAME 22. WASHER
4. LIFT HAND LEVER 23. LOCKOUT STRAP
5. TILT HAND LEVER 24. NUT PLATE
6. 3RD FUNCTION HAND LEVER 25. NUT
7. 4TH FUNCTION HAND LEVER 26. PIN
8. CAPSCREW 27. SPRING
9. WASHER 28. PIVOT
10. LOCKWASHER 29. CRANK
11. NUT 30. CRANK
12. STANDOFF 31. SPACER (NOT SHOWN)
13. STANDOFF 32. LINK
14. CAPSCREW 33. COTTER PIN
15. KNOB 34. PIN
16. PIN 35. ROCKER ARM
17. LATCH ROD 36. SNAP RING
18. LATCH 37. PIVOT PIN
19. CAPSCREW 38. FLANGE BEARING
2. If the return springs were removed from the con- slings, etc.) are suitable and of adequate capac-
trol spools, install the spring retainers. During ity to lift the hydraulic control valve. The hy-
assembly, use new O-rings for the parts of the tilt draulic control valve can weigh 11.4 to 13.6 kg
control spool. Do not damage the O-rings during (25 to 30 lb) without any attachments.
installation.
1. Align and secure the hydraulic control valve to
3. Lubricate the spools with clean hydraulic oil. En- the supporting bracket by installing the three
sure spool is free of contamination. Carefully in- mounting capscrews (23), washers (24), lock-
stall the spools in the valve body. Install the seal washers (25), and nuts (26).
retainers and the covers for the return springs.
2. Install the pins (8), washers (28), if applicable,
4. Install the relief valves. Adjust the relief settings and cotter pins (7) connecting the lower linkage
for the hydraulic system as described in Pressure to the hydraulic control valve.
Relief Valve Check and Adjustment.
3. Ensure that the three upper rubber channels (21)
5. Connect all electrical connections to the valve are properly installed on the supporting bracket.
switches. While supporting the hydraulic control valve as-
sembly, carefully position the supporting bracket
INSTALL in the lower rubber channels (20) and tighten
the two capscrews (16), washers (17), lockwash-
The hydraulic control valve assembly is mounted to ers (18), nuts (19), and brackets (15) securing the
a supporting bracket, which is secured to the frame bottom of the supporting bracket to the frame.
of the truck. To install these parts, use the following
procedures and see Figure 6. 4. Install the three brackets (15), capscrews (16),
washers (17), lockwashers (18), and nuts (19) se-
WARNING curing the top of the supporting bracket to the
frame.
The hydraulic control valve is heavy. Be sure
that all lifting devices (hoists, cables, chains, 5. Connect the hydraulic wiring harness connector
to the main wiring harness.
11
1. THROUGH-BOLT 9. TILT SPOOL 17. SPRING CUP

2. AUXILIARY SECTION 10. TILT SECTION 18. SCREW
3. O-RING 11. LIFT/LOWER SECTION 19. END CAP
4. SEAL 12. LIFT/LOWER SPOOL 20. TILT CONTROL SPOOL
5. RETAINER 13. SECONDARY RELIEF VALVE 21. BRACKET
6. AUXILIARY SPOOL 14. PRIMARY RELIEF VALVE 22. SWITCH
7. SPRING 15. INLET SECTION 23. OUTLET SECTION
8. CHECK VALVE 16. PLUG
Figure 8. Main Control Valve
12
6. Remove caps and plugs from the hydraulic hoses 8. Install the battery. Follow the instructions in Pe-
and fittings. Connect the pressure and supply riodic Maintenance 8000 SRM 1079 for bat-
line to the pump. Connect all remaining hy- tery installation information. Connect the bat-
draulic hoses at the fittings. See Figure 9. tery connector.
7. Check the level of hydraulic oil in the tank. If 9. Operate the lift, tilt, and auxiliary controls.
necessary, add hydraulic oil. Check for leaks from the hydraulic hoses and
valve connections.
10. Install the lower cover.
1. AUXILIARY 2 4. LIFT
2. AUXILIARY 1 5. TO FILTER
3. TILT 6. FEED FROM PUMP
Figure 9. Hydraulic Line Arrangement
13
Pressure Relief Valve Check and Adjustment 2000 SRM 1085
Pressure Relief Valve Check and Adjustment

NOTE: The main control valve has two relief valves: 2. Loosen the jam nut on the relief valve.
a primary relief valve and a secondary relief valve.
The primary relief valve is in the inlet section of the 3. Operate the hydraulic system to warm the oil
control valve. The secondary relief valve is in the temperature to 55 to 65 C (131 to 149 F).
outlet section of the control valve. See Figure 10.
4. Tilt the mast backward until it stops. Hold the
lever and check the reading of the gauge when
PRIMARY RELIEF VALVE
the relief valve opens. Turn the adjustment
screw, as necessary, to change the setting. The
WARNING correct setting is 13.8 MPa (2000 psi). Tighten
Never allow anyone under a raised carriage. the jam nut when the adjustment is correct.
Do not put any part of your body in or through
the lift mechanism unless all parts of the mast 5. Remove the gauge when the checks are complete.
are completely lowered and the key switch is
OFF.
1. Insert a tee fitting into the pressure supply line

to the mast. Connect a 25 MPa (3600 psi) gauge
to the tee fitting.
2. Loosen the jam nut.
3. Operate the hydraulic system to warm the oil

temperature to 55 to 65 C (131 to 149 F).
CAUTION
During this test, the mast must be fully ex-
tended. Make sure there is enough overhead
clearance in the building, or do the test out-
doors.
4. Raise the mast until it stops. Hold the lever and

check the reading of the gauge when the relief
valve opens. Turn the adjustment screw, as nec-
essary, to change the setting. The correct setting
is 17.9 MPa (2600 psi). Tighten the jam nut when 1. ADJUSTMENT SCREW
the adjustment is correct. 2. JAM NUT
3. PRIMARY RELIEF VALVE
5. Remove the gauge when the checks are complete. 4. SECONDARY RELIEF VALVE
SECONDARY RELIEF VALVE Figure 10. Relief Valve Locations
1. Insert a tee fitting into the tilt or auxiliary cir-

cuit. Connect a 20 MPa (3000 psi) gauge to the
tee fitting.
14
Troubleshooting
Slow or no movement of Air is in the hydraulic system. Remove air from hydraulic system.
cylinders.
The hydraulic pump is worn or dam- Repair or replace hydraulic pump.

aged.
Restriction in the hydraulic lines. Repair hydraulic lines.
Cylinder seals are damaged. Repair cylinders.
Load is greater than capacity. Reduce load.
Linkage is disconnected or damaged. Repair and adjust linkage for control

levers.
Pressure relief valve(s) is not ad- Repair or adjust relief valve(s).

justed correctly or is damaged.
Large leaks between spool and bore. Replace valve section.
Switch plates are not installed or ad- Check position of switch plates.
justed correctly.
Pump motor fails to turn on. Failed control valve switch. Replace switch.
Open circuit. Check wiring connections. Check

wiring continuity.
Switch plates are not installed or ad- Check position of switch plates.
justed correctly.
Oil leaks at the end of a Seal for spool is damaged. Replace seal.
spool.
Spool is damaged. Replace valve section.
Valve body is damaged. Replace valve section.
Hydraulic pressure is above Pressure relief valve(s) is not ad- Repair or adjust relief valve(s).
specifications. justed correctly or is damaged.
Restriction in return line. Clean or replace return line or filter.
15
Tilt cylinders extend when Cylinder seal has leaks. Repair tilt cylinders.
the tilt spool is in the NEU-
TRAL position.
Oil leaks between control valve spool Replace valve section.

and bore.
Hydraulic lines have leaks. Repair or tighten lines or fittings.
Tilt cylinders extend sud- Check valve for tilt spool is damaged. Replace check valve.
denly when the tilt spool is
moved to BACK TILT posi-
tion.
Tilt cylinders extend sud- Tilt control spool inside the tilt spool Replace valve section.
denly when the tilt spool is is damaged.
moved to FORWARD TILT
position.
Lift cylinders retract when Check valve for the lift spool is dam- Replace check valve.
the lift spool is in the NEU- aged.
TRAL position.
Cylinder seals have leaks. Repair lift cylinders.
Hydraulic lines have leaks. Repair or tighten lines or fittings.
Leaks between the lift spool and the Replace valve section.
bore.
Spool will not move or is dif- Linkage is disconnected or damaged. Repair and adjust linkage.
ficult to move.
Return spring is damaged. Replace spring.
The spool or bore is damaged. Replace valve section.
Spool will not return to Linkage is disconnected or damaged. Repair and adjust linkage.
NEUTRAL.
Return spring is damaged. Replace spring.
Dirt between spool and the bore. Clean valve.
Spool is bent or damaged. Replace valve section.
16

ELECTRO-HYDRAULIC
CONTROL VALVE
J1.6-2.0XMT (J30-40ZT) [J160]
PART NO. 1554632 2000 SRM 1086

SAFETY PRECAUTIONS

trucks.
nance section.
manual:
WARNING
CAUTION
Electro-Hydraulic Control Valve Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Description ......................................................................................................................................................... 1
Electro-Hydraulic Control System................................................................................................................ 1
Electro-Hydraulic Control Valve................................................................................................................... 2
Valve Driver Module...................................................................................................................................... 5
Manual Lowering Valve ................................................................................................................................ 5
Hydraulic Lever Console ............................................................................................................................... 5
Electro-Hydraulic Control Valve ....................................................................................................................... 5
Remove ........................................................................................................................................................... 5
Disassemble ................................................................................................................................................... 6
Assemble ........................................................................................................................................................ 7
Lift Valve Section ...................................................................................................................................... 7
Tilt/Auxiliary Valve Sections .................................................................................................................... 7
Valve Spool Coils ....................................................................................................................................... 8
Fittings....................................................................................................................................................... 8
Install ............................................................................................................................................................. 8
Check and Adjust........................................................................................................................................... 9
Tilt Counterbalance Valve ........................................................................................................................ 9
Main Relief Valve ...................................................................................................................................... 9
Auxiliary Relief Valve ............................................................................................................................... 9
Valve Driver Module .......................................................................................................................................... 9
Remove ........................................................................................................................................................... 9
Install ............................................................................................................................................................. 10
Hydraulic Lever Console ................................................................................................................................... 10
Remove ........................................................................................................................................................... 10
Disassemble ................................................................................................................................................... 10
Covers ........................................................................................................................................................ 10
Hydraulic Control Lever ........................................................................................................................... 10
Main PC Board .......................................................................................................................................... 10
Assemble ........................................................................................................................................................ 11
Main PC Board .......................................................................................................................................... 11
Hydraulic Control Lever ........................................................................................................................... 11
Covers ........................................................................................................................................................ 11
Install ............................................................................................................................................................. 11
Troubleshooting Chart................................................................................................................................... 12
J1.6-2.0XMT (J30-40ZT) [J160]

"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
General
This section contains the description, repair, and hydraulic pump, or hydraulic pump motor. See
troubleshooting procedures for the electro-hydraulic the section Electrical System 2200 SRM 1078 for
control valve. This section contains information on information on the Pump Controller. See the section
the control valve, lever console, and the valve driver Hydraulic System 1900 SRM 1077 for information
module. These components comprise the electro-hy- on the hydraulic pump and motor. See the sec-
draulic control system. This section does not contain tion Diagrams 8000 SRM 1081 for information on
information on the hydraulic pump motor controller, wiring.
Description
ELECTRO-HYDRAULIC CONTROL
SYSTEM
The electro-hydraulic control system consists of the
control valve, lever console, valve driver module, hy-
draulic pump and motor, and pump motor controller.
See Figure 1. The lever console, valve driver mod-
ule, and pump motor controller communicate with
each other via the CANbus communication system on
the lift truck. This allows the lever console to send
signals to the valve driver module over a small ca-
ble. Signals from the levers are received by the valve
driver module and are then sent to the electro-hy-
draulic valve solenoid coils to open or close the valve
spools. The lever signal is also received by the slave
controller in the traction control through the CAN-
bus. The slave controller uses these signals to turn
on the pump motor. Pump speed is variable up to the
maximum speed preset in the pump motor controller
for the required hydraulic function. See Figure 2.
1. TRACTION/PUMP MOTOR CONTROLLER

2. LEVER CONSOLE
3. ELECTRO-HYDRAULIC CONTROL VALVE
4. VALVE DRIVER MODULE
5. PUMP AND MOTOR ASSEMBLY
6. SEAT
Figure 1. Component Location
1
Description 2000 SRM 1086
Figure 2. Logic Diagram - Electro-Hydraulic Controls
ELECTRO-HYDRAULIC CONTROL VALVE The auxiliary control sections contain a spring-cen-

tered spool, two solenoid coils, a pressure compen-
The electro-hydraulic control valve is modular in de- sating valve, and two crossover relief valves.
sign. Control valve sections are stacked together to
assemble the control valve assembly. Control valve The valve is fully proportional. This means the valve
sections may be combined to provide a two-, three-, spools move in proportion to the amount of movement
or four-spool valve. See Figure 3 and Figure 4. of the correct hydraulic lever. A small movement of
the hydraulic lever will result in a small movement
The basic valve consists of a lift section and a tilt of the valve spool. The movement of the valve spool
section. Additional sections are added to the valve will allow pressurized oil from the hydraulic pump
to provide auxiliary hydraulic functions. to flow to a hydraulic function. Further movement of
the hydraulic lever will result in an increased flow of
The lift section contains a lift proportional control
hydraulic oil through the valve.
cartridge, lower proportional control cartridge, relief
valve, manual lowering valve, and a load check valve.
The tilt section contains a spring-centered spool, two

solenoid coils, a counterbalance valve, and a pressure
compensating valve.
2
The valve spool movement is controlled by the valve spool determines the movement of the spool.
amount of electrical current sent to the solenoid coil Moving the spool further from the center position
attached to the spool. Varying the current to the increases the flow of hydraulic oil through the valve.
1. MANUAL LOWERING VALVE 8. AUXILIARY CONTROL #1 (WORK PORT B)

2. LIFT CONTROL (WORK PORT H) 9. TILT CONTROL (WORK PORT B)
3. TILT CONTROL (WORK PORT A) 10. COUNTERBALANCE VALVE
4. AUXILIARY CONTROL #1 (WORK PORT A) 11. LOWER CONTROL (WORK PORT R)
5. AUXILIARY CONTROL #2 (WORK PORT A) 12. MAIN RELIEF VALVE
6. AUXILIARY RELIEF VALVE 13. LOAD CHECK
7. AUXILIARY CONTROL #2 (WORK PORT B)
Figure 3. Electro-Hydraulic Control Valve
3
1. TILT CYLINDERS 10. HYDRAULIC TANK

2. TILT COUNTERBALANCE VALVE 11. FILTER
3. LIFT CYLINDERS 12. MAIN RELIEF VALVE
4. LOWERING CONTROL (INTERNAL) 13. MANUAL LOWERING VALVE
5. LOWERING CONTROL (EXTERNAL) 14. TILT SPOOL
6. LOWER PROPORTIONAL CARTRIDGE 15. PRESSURE COMPENSATING VALVE
7. LOAD CHECK VALVE 16. AUXILIARY SPOOL
8. LIFT PROPORTIONAL CARTRIDGE 17. CROSSOVER RELIEF VALVE
9. HYDRAULIC PUMP 18. SUPPLY PRESSURE GAGE PORT
Figure 4. Control Valve Schematic
4
2000 SRM 1086 Electro-Hydraulic Control Valve
VALVE DRIVER MODULE the levers needed to control the hydraulic functions
supplied with the lift truck. The levers are paddle
The valve driver module is a solid-state logic device shaped and can be moved in the forward or back-
that receives signals from the control lever console ward direction. Lever location and operation are
over the CANbus and sends signals to the electro- consistent with the requirements of ANSI B56.1
hydraulic valve. and are identical in operation to the levers supplied
with the standard manual control valve. Each lever
MANUAL LOWERING VALVE has a Hall Effect sensor that produces the output
signal to a microprocessor in the lever module. The
CAUTION microprocessor converts the signals so they can be
Turn the manual lowering valve counterclock- sent over the CANbus to the valve driver module
wise to the closed position before placing the and the slave controller in the traction control.
lift truck into service.
Each individual control lever produces an electrical
The mast may be lowered using the manual lowering signal that is proportional to the amount of lever
valve located on the Lift/Lower section of the main movement - the greater the movement of the lever,
control valve. See Figure 3. Turn the lowering valve the greater the output signal from the lever. Power
screw clockwise into the valve housing to open the to the lever console is 12 volts supplied from the valve
lowering valve to lower the mast. driver module.
HYDRAULIC LEVER CONSOLE

The hydraulic lever console is mounted on the
right-hand armrest of the seat. The console contains
Electro-Hydraulic Control Valve

REMOVE 4. Turn the key switch to the OFF position.
5. Release the locking mechanism retaining the

WARNING hood and raise the hood.
Before making any repairs to the control valve,
tilt the forks until they are parallel with the
floor. Lower the mast until the forks rest on
WARNING
the floor. This action will prevent the mast The battery is heavy and should be removed
from lowering suddenly when the hydraulic carefully to avoid causing damage or injury.
lines are disconnected. Use care to avoid injury. Do NOT put hands,
arms, feet, or legs between the battery and a
solid object.
WARNING
Put blocks on both sides (front and back) of the 6. Disconnect the battery and separate the connec-
drive tires. tor halves. Remove the battery to gain access
to the mounting capscrews for the control valve.
1. Turn the key to the ON position. Follow the instructions in the section Periodic
Maintenance 8000 SRM 1079 for battery re-
2. To relieve hydraulic pressure from the lift circuit,
moval information.
hold the lower lever in the forward position to
completely lower the forks. 7. Remove the floor plates to gain access to the con-
trol valve.
3. To relieve hydraulic pressure in the tilt circuit,
hold the tilt lever in the forward position to com-
pletely tilt the forks forward.
5
Electro-Hydraulic Control Valve 2000 SRM 1086
2. Remove the fittings from the control valve. In-

WARNING spect fittings for damage and replace any dam-
Hydraulic oil is hot after system operation and aged fittings.
can cause burns. Do not disconnect any hy-
draulic lines until the oil in the system is cool. 3. The entire control valve may be disassembled by
removing the nuts, washers, and end plate from
NOTE: Removal of the control valve may result in the the valve assembly.
spillage of hydraulic oil as lines are removed. Place
an appropriate container under the lift truck in the 4. The main control valve sections may be sepa-
area of the control valve to catch any spillage. rated, as required to service individual compo-
nents, by sliding them off the two valve mounting
8. Disconnect all electrical connections from the studs attached to the lift valve section. The sec-
valve solenoids. Remove the screw from the tions are connected by O-rings, which are held in
front of the solenoid coil connectors and pull the place by the next valve body section.
connector away from the coil. Tag all wires to
assist with reassembly of the control valve. 5. Valve section coils may be removed by removing
the retaining ring, washer, and O-ring at the top
9. Mark and disconnect the hydraulic hoses at the of the valve spool. Slide the coil off the valve.
fittings on the control valve. Drain any excess Note the orientation of the coil and the connector
hydraulic oil into a suitable container. Install for reassembly.
plugs in the hydraulic lines to prevent leaking
and to prevent dirt from entering the system. 6. Remove the valve spools by removing the four
socket head capscrews retaining the spool end
cap to the valve body. Remove the end cap and
WARNING slide the spool from the valve body.
The electro-hydraulic valve assembly is heavy.
Be sure all lifting devices (hoists, chains, CLEAN AND INSPECT
slings, etc.) are suitable and of adequate ca-
pacity to lift the control valve. The hydraulic
control valve can weigh 11.4 to 13.6 kg (25 to
WARNING
30 lb) without any attachments. Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
10. Locate and remove the top valve retainer clamp. cleaning solvents, always follow the solvent
Carefully lift the control valve out of the two manufacturer’s recommended safety proce-
bottom valve retainers and remove from the lift dures.
truck.
1. Clean only the metallic parts of the control valve
11. Move the control valve to a workbench for disas- with solvent. Do not get solvent in the electrical
sembly. Clean the exterior of the control valve connectors or other plastic parts.
before attempting repairs.
2. Check the spools and bores for wear or damage.
DISASSEMBLE If a spool or the bores have damage, the control
valve section must be replaced. Make sure the
Disassemble the main control valve as necessary for spools move freely in the section bores.
repairs. Most repairs to the main control valve are
for the replacement of O-rings and seals to stop leaks. 3. Inspect check valves and relief valves for dam-
The passages in the spools and valve body are small age. Replace the parts as necessary.
and can need cleaning if the hydraulic oil becomes
4. Check all O-ring mounting seats for nicks or
dirty. Normally, a section must be replaced if the
burrs. Replace any section that has a damaged
spool or valve section is damaged. See Figure 5 for
O-ring seat.
the following disassembly procedures.
1. Remove the valve assembly from the valve

mounting plate.
6
2000 SRM 1086 Electro-Hydraulic Control Valve
1. MAIN VALVE SECTIONS 4. VALVE MOUNTING STUDS

2. VALVE SECTION COILS 5. WASHER
3. END PLATE 6. NUT
Figure 5. Control Valve Assembly
ASSEMBLE Tilt/Auxiliary Valve Sections

See Figure 5 for the following assembly procedures. 1. Carefully slide the valve spool into the valve
body. Install the spool end cap and torque
the four socket head capscrews to 4.7 N•m
CAUTION (41.60 lbf in).
Before installing the parts into the valve body,
make sure all parts are clean. Replace all seals 2. Install new O-ring seals between the sections.
and O-rings.
3. Slide the section onto the two valve mounting
Lubricate moving parts with clean hydraulic oil dur- studs attached to the lift section.
ing assembly of the control valve.
4. Assemble the tilt section next to the lift section
Lift Valve Section with the “B” port at the bottom of the valve.
Install the lift and lower cartridges into the lift 5. Assemble the auxiliary sections with the “A” port
valve section body. Torque the cartridges to 40 N•m at the bottom of the valve.
(29.5 lbf ft).
6. Install the end plate, washers, and nuts. Torque
the nuts to 23 N•m (16.96 lbf ft).
7
Electro-Hydraulic Control Valve 2000 SRM 1086
Valve Spool Coils

1. Install coils on spool end caps.
2. The coil connections should be oriented toward

the front of the valve and to the top or the bottom
of the valve as shown in Figure 6.
3. Install the O-rings, washers, and retaining rings

to retain the coil to the spool end cap.
Fittings
Install fittings into the valve assembly. See Figure 6.
1. WASHER 7. WASHER
2. CAPSCREW 8. NUT
3. CAPSCREW 9. ISOLATOR
4. WASHER 10. BRACKET
5. CAPSCREW 11. MOUNTING PLATE
6. WASHER
Figure 7. Control Valve Mounting
3. Install the pressure line from the hydraulic

pump.
4. Install hoses to auxiliary and tilt sections in the

order they were removed.
5. Install the return line between the valve and the

Figure 6. Fitting Orientation hydraulic tank.
INSTALL 6. Install the pressure line to the mast.
1. Install the valve assembly onto the valve mount- 7. Install all wiring connections to the valve.
ing plate. See Figure 7. Install the capscrews
and washers through the back of the mounting 8. Check hydraulic fluid in the hydraulic tank and
plate into the valve. Torque capscrews (2) to replenish if needed.
19 N•m (14 lbf ft). Torque capscrew (3) to 8 N•m
(6 lbf ft). WARNING
2. Install the valve and mounting plate into the The battery is heavy and should be installed
truck frame. Set the mounting plate into the carefully to avoid causing damage or injury.
two bottom isolators attached to the frame. In- Use care to avoid injury. Do NOT put hands,
stall the top isolator and mounting hardware. arms, feet, or legs between the battery and a
See Figure 7. Torque the mounting hardware to solid object.
38 N•m (28 lbf ft).
9. Install battery.
10. Connect battery to the truck.
8
2000 SRM 1086 Valve Driver Module
11. Turn the key to the ON position. 3. Press the tilt lever forward to open the tilt valve.
12. Operate the lift truck through all hydraulic func- The tilt counterbalance valve is non-adjustable with
tions and check for correct operation. Ensure all a setting of 20.7 ±0.5 MPa (3000 ±75 psi).
hydraulic functions operate in the correct direc-
tion according to the hydraulic function label on Main Relief Valve
the control lever. If the direction is incorrect, re-
verse the hydraulic hoses at the correct valve sec- 1. Install a 25 MPa (3600 psi) pressure gauge to
tion. the supply pressure gauge port on the side of the
electro-hydraulic valve. See Figure 4.
13. Check for leaks.
2. Loosen the lock nut at the base of the adjustment
14. Remove drip pan used during the repair. screw.
15. Remove all blocks from the lift truck wheels. 3. Move the adjustment screw in or out of the valve
to adjust the relief pressure.
CHECK AND ADJUST
4. The pressure should be set at 17.9 MPa
Tilt Counterbalance Valve (2600 psi).
1. Tilt the mast to the full back position with a load 5. Lock the adjustment screw in place with the lock
on the forks. nut.
2. Disable the hydraulic motor so the motor cannot Auxiliary Relief Valve
run.
The auxiliary relief valves are non-adjustable with a
NOTE: If after completing Step 3 the mast does not setting of 13.8 ±0.5 MPa (2000 ±75 psi).
begin to drift forward, the counterbalance valve is
working properly. If after completing Step 3 the mast
begins to drift forward, the counterbalance valve is
not working properly.
Valve Driver Module

There are no serviceable parts within the valve
driver module. If there is an internal fault within
the valve driver module, the module must be re-
placed.
REMOVE
The valve driver module is located on the front cowl
underneath the dash panel on the right hand side of
the lift truck.
1. Unplug the two connectors from the main har-

ness and tag them for later installation.
2. Remove the capscrews, lockwashers, and nuts

holding the valve driver module to the front cowl.
See Figure 8. 1. VALVE DRIVER 3. LOCKWASHER
MODULE 4. NUT
3. Remove the valve driver module from the lift 2. CAPSCREW
truck.
Figure 8. Valve Driver Module
9
Hydraulic Lever Console 2000 SRM 1086
INSTALL 2. Install the valve driver module using the cap-

screws, lockwashers, and nuts as shown in Fig-
1. Locate the mounting holes for the valve driver ure 8.
module on the front cowl.
Hydraulic Lever Console

REMOVE 2. Separate the two halves of the console cover.
1. Push down on the latch on the right-hand side of 3. Place the assembly upside down on the bench.
the arm rest housing the lever module and raise
the arm rest. Hydraulic Control Lever
2. Locate and disconnect the electrical connector at NOTE: The individual hydraulic lever assemblies can
the back of the lever module. See Figure 9. Tag be removed from the lever console assembly without
the connector for later installation. removing the console mounting plate or the main PC
board.
1. Disconnect the lever wiring connector from the

main PC board. Press the locking tab next to
the wiring coming from the levers to release the
connector from the PC board.
2. Remove the four screws retaining the lever as-

sembly to the upper cover.
3. Remove the two screws holding the lever PC

board to the lever assembly.
Main PC Board
1. Clip the wire tie holding the lever harness to the
lever mounting plate.
1. LEVER MODULE 3. WASHER 2. Remove the two screws holding the console
2. NUT 4. LOCKWASHER mounting plate to the upper cover.
Figure 9. Lever Module Mounting 3. Disconnect the lever wiring connectors from the
3. Remove the four nuts, washers, and lockwashers main PC board. Press the locking tab next to
from the back of the lever module. See Figure 9. the wiring coming from the levers to release the
Take care when removing that the lever module connector from the PC board.
does not fall when the capscrews are removed. 4. Remove the console mounting plate.
4. Remove the lever module from the lift truck. 5. Remove the four screws retaining the main PC
board to the upper cover.
DISASSEMBLE
Covers
1. Remove the four screws from the bottom of the
lever console assembly.
10
2000 SRM 1086 Hydraulic Lever Console
ASSEMBLE Legend for Figure 10
Main PC Board 1. LEVER PC BOARD

2. MAIN PC BOARD
1. Install the main PC board to the upper cover us-
NOTE: Installing the lever assembly incorrectly will
ing the four PC board mounting screws.
result in incorrect operation of the function operated
2. Insert the PC board wiring harness through the by the lever.
opening in the console mounting plate.
3. Install the lever assembly wiring connector to the
3. Install the mounting plate to the upper cover us- main PC board. Insert the connector into the
ing the two mounting screws. Wire-tie the har- main PC board until the connector lock is en-
ness using the wire-tie connection on the mount- gaged.
ing plate.
Covers
4. Install the lever assembly wiring connectors to
the main PC board. Insert the connector into Install the lower cover to the upper cover using the
the main PC board until the connector lock is four mounting screws.
engaged.
INSTALL
Hydraulic Control Lever 1. Place the lever console assembly on the end of the
1. Insert the lever PC board into the lever and in- right-hand arm rest. See Figure 9.
stall the two mounting screws.
2. Install the washers, lockwashers, and nuts.
2. Ensure the sealing ring is properly installed in
3. Connect the connector from the seat wiring har-
the lever assembly. Install the lever assembly to
ness.
the upper cover with the four mounting screws.
Ensure the wiring on the lever PC board is on the 4. Connect the battery.
left hand side as shown in Figure 10.
5. Turn the key to the ON position.
6. Activate all levers and ensure all hydraulic func-

tions operate correctly.
Figure 10. Lever Assembly PC Board

Installation
11
Troubleshooting
When a fault occurs in the electrical circuits of the Adjustments, and Troubleshooting 2200 SRM
electro-hydraulic controls, an error code will be 1087 for operation of the dash display and a com-
displayed on the dash display. See the listing of plete explanation of the electro-hydraulic error codes
error codes below. See the section AC Motor Con- used to troubleshoot the electro-hydraulic controls
trollers/Display Panel, Description, Checks, system.
Table 1. Error Codes
Code 42 Lift control temperature too high. Code 270 Error in lift hydraulic lever.
Code 91 Lift motor temperature too high. Code 271 Error in tilt hydraulic lever.
Code 95 Lift motor brushes worn. Code 272 Error in sideshift hydraulic lever.
Code 128 Lift motor armature current too Code 273 Error in 4th function hydraulic
high. lever.
Code 201 Arm rest switch not closed. Code 276 Lift driver is shorted in valve driver
module.
Code 202 Hydraulic oil low. Code 277 4th function driver is shorted in
valve driver module.
Code 208 Incorrect lift motor start. Code 279 Tilt driver is shorted in valve driver
module.
Code 242 Master controller CAN error with Code 280 Sideshift driver is shorted in valve
hydraulic lever console. driver module.
Code 243 Master controller CAN error with Code 282 Load hold driver is shorted in valve
valve driver module. driver module.
Code 247 Valve driver module CAN error with Code 283 One of the valve coils is shorted.
dash display.
Code 260 Incorrect voltage at the motor.
TROUBLESHOOTING CHART
Slow or no movement of Air is in hydraulic system. Remove air from hydraulic system.
cylinders.
Hydraulic pump is worn or damaged. Repair or replace hydraulic pump.

See the section Hydraulic System
1900 SRM 1077 for repair proce-
dures.
Restriction in hydraulic lines. Repair hydraulic lines.
12
Slow or no movement of Cylinder seals are damaged. Repair cylinder. See the section
cylinders. (Cont.) Tilt Cylinders 2100 SRM 103 for
tilt cylinder repair. See the section
Mast, Repairs 4000 SRM 522 for
lift cylinder repair.
Load is greater than capacity. Reduce the load.
Pressure relief valve(s) is not ad- Repair or adjust relief valve(s). See
justed correctly or is damaged. Main Relief Valve.
Incorrect operation of solenoid Check display for fault code. See the
valves. section AC Motor Controllers/Dis-
play Panel, Description, Checks,
Adjustments, and Troubleshoot-
ing 2200 SRM 1087 for fault code in-
formation.
Manual lowering valve is open. Close manual lowering valve on Lift/

Lower section of main control valve.
Pump motor fails to turn on. Failure of function lever. Check display for fault code. See the
section AC Motor Controllers/Dis-
formation.
Failure of pump motor controller. Check display for fault code. See the
formation.
Failure of valve driver module. Check display for fault code. See the
formation.
Failure of CANbus. Check display for fault code. See the

formation.
13
Pump motor fails to turn on. Failure of pump motor. Check display for fault code. See the
(Cont.) section AC Motor Controllers/Dis-
formation.
Oil leaks at end of spool. Seal for spool is damaged. Replace the seal.
Spool is damaged. Replace the spool.
Valve body is damaged. Replace the valve section.
Tilt cylinders extend when Cylinder has leaks. Repair or replace cylinder.
tilt spool is in the neutral
position.
Leakage between the tilt spool and Replace the valve section.
bore.
Hydraulic lines are leaking. Repair or tighten lines.
Lift cylinder(s) retracts Load hold check valve is damaged. Inspect check valve for contamina-
when lift spool is in the tion or damage. Clean or replace
neutral position. check valve.
Cylinder seals have leaks. Repair lift cylinder.
Hydraulic lines have leaks. Repair or tighten lines.
Leakage between lift spool and bore. Replace the valve section.
No function operation. Failure of function lever. Check display for fault code. See the
formation.
Failure of function spool solenoid Check display for fault code. See the
coil. section AC Motor Controllers/Dis-
formation.
14
No function operation. Failure of valve driver module. Check display for fault code. See the
(Cont.) section AC Motor Controllers/Dis-
formation.
Failure of CANbus. Check display for fault code. See the

formation.
Failure of pump motor. Check display for fault code. See the
ing 2200 SRM 1087 for fault code
information. See the section Hy-
draulic System 1900 SRM 1077 for
repair procedures.
Failure of pump motor controller. Check display for fault code. See the
formation.
No or low flow from pump. Worn pump. Repair or replace pump. See the sec-
tion Hydraulic System 1900 SRM
1077 for repair procedures.
Incorrect relief valve setting. Set relief valve to correct pressure

setting. See Main Relief Valve.
15
NOTES
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16

TILT CYLINDERS
ALL MODELS EXCEPT
H3.50-5.50XM (H70-120XM) [K005, L005]
S3.50-5.50XM (S70-120XM) [E004, F004]
PART NO. 910102 2100 SRM 103

SAFETY PRECAUTIONS

nance section.
manual:
WARNING
CAUTION
Tilt Cylinders Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Description ......................................................................................................................................................... 1
Tilt Cylinder Repair ........................................................................................................................................... 1
Remove ........................................................................................................................................................... 1
Disassemble ................................................................................................................................................... 1
Clean .............................................................................................................................................................. 1
Assemble ........................................................................................................................................................ 2
Tilt Cylinders With O-Ring or Single-Lip Seals ...................................................................................... 2
Tilt Cylinders for XM and XMS Models ................................................................................................... 3
Tilt Cylinders for H700-800A and Early Model H700-920B ................................................................... 4
Install ............................................................................................................................................................. 5
Tilt Cylinders Using Chevron Packing .................................................................................................... 6
Install..................................................................................................................................................... 7
Tilt Cylinder Leak Check .................................................................................................................................. 9
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment .................................................................................... 10
Torque Specifications ......................................................................................................................................... 11
Piston Rod Nut............................................................................................................................................... 11
Retainer.......................................................................................................................................................... 12
All Models except

H3.50-5.50XM (H70-120XM) [K005, L005]
S3.50-5.50XM (S70-120XM) [E004, F004]

"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
2100 SRM 103 Tilt Cylinder Repair
General
This section has a description and the repair proce- number and the design of the parts can be different,
dures for several different types of tilt cylinders. The but the operation of the tilt cylinders is the same.
Description
The tilt cylinders (Figure 2, Figure 3, Figure 4, and tank. To retract the cylinder rod (tilt backward), the
Figure 5) are used to move the mast forward and oil enters the port in front of the piston. The oil pres-
backward. To extend the cylinder rod (tilt forward), sure pushes the cylinder rod into the tilt cylinder.
oil enters the tilt cylinder port behind the piston. The The oil behind the piston returns to the hydraulic
oil pressure pushes the cylinder rod out of the cylin- tank.
der. Oil in front of the piston returns to the hydraulic
Tilt Cylinder Repair

REMOVE 2. Remove the retainer from the tilt cylinder. Re-
move the rod and piston from the cylinder.
WARNING 3. Disassemble the tilt cylinder as necessary. See
Before removing the tilt cylinder(s), tilt the Figure 2, Figure 3, Figure 4, and Figure 5.
mast forward. Use a chain to hold the mast to
the frame, and prevent the mast from moving CLEAN
forward.
1. Disconnect the hydraulic lines at the tilt cylinder. WARNING

Install caps on the hydraulic lines and ports. Cleaning solvents can be flammable and toxic
cleaning solvents, always follow the solvent
WARNING
manufacturer’s recommended safety proce-
Do not push the anchor pins out of the rod end dures.
with your fingers. Do not permit the tilt cylin-
ders to drop and cause damage. Compressed air can move particles so that they
cause injury to the user or to other personnel.
2. Remove the retainers for the anchor pins. Push Make sure that the path of the compressed air
the anchor pins out of the rod end with a tool. is away from all personnel. Wear protective
3. Use a lifting device to move large tilt cylinders. goggles or a face shield to prevent injury to the
Remove the anchor pins from the frame anchors. eyes.
Remove the tilt cylinder from the frame. Clean all parts in solvent and dry with compressed
air.
DISASSEMBLE
1. Put the tilt cylinder in a vise with soft jaws. Re-
move the rod end from the rod.
1
Tilt Cylinder Repair 2100 SRM 103
ASSEMBLE 2. Install the O-ring, seal ring, and guide ring on

the piston. The seal ring must be heated before
Tilt Cylinders With O-Ring or Single-Lip installation. After heating, it must be pushed
Seals into its groove using a ring compressor. Let the
seal ring cool and return to its normal shape.
NOTE: Always use new seals and O-rings. Make sure
all parts are clean. Lubricate all parts with clean 3. If used, install the O-ring and the backup ring in
hydraulic oil. the groove of the outer retainer. Install the rod
seal (O-ring toward the piston) and wiper seal in
NOTE: During 1980 and 1981, a change was made in the inner retainer.
the tilt cylinders used in most lift trucks. The O-ring
seal between the retainer and the cylinder shell was 4. Install the retainer on the piston rod. Install
moved from above the threads to the area below the the piston and rod assembly and the retainer in
threads. A backup ring was added to increase the the cylinder. If used, install the O-ring on the
strength of the O-ring. The assembly of the tilt cylin- retainer. Tighten the retainer to specifications
ders is the same, but caution must be used so that the given in Torque Specifications.
O-ring seal is not damaged by the threads.
NOTE: After assembly is complete, install the rod
1. Install the O-ring inside the piston bore. See Fig- end on the piston rod. Tighten the capscrew on the
ure 1. Install the piston on the piston rod. Make rod end as specified in Mast section for your specific
sure the O-ring is not damaged. Tighten the nut lift truck.
on the piston rod to the specifications given in
Torque Specifications.
1. PISTON ROD 8. CYLINDER SHELL

2. PISTON RING 9. O-RING
3. O-RING 10. BACKUP RING
4. O-RING 11. RETAINER
5. PISTON 12. SEAL RING
6. GUIDE RING 13. WIPER RING
7. NUT 14. SPACER (SOME MODELS)
Figure 1. Tilt Cylinders With O-Ring or Single-Lip Seals
2
Tilt Cylinders for XM and XMS Models is not damaged. Tighten the nut on the piston
rod to the value shown in Torque Specifications.
NOTE: The following procedure is for these models:
S/H/E/2.00-3.00XM (S/H/E/40-65XM), J2.00-3.00XM 2. Install a new wiper and rod seal. Install the
(J40-60XM, J40-60XM 2) (A216), J2.00-3.00XM O-ring and backup ring onto the retainer.
(J40-60Z) (A416), J1.60-2.00XMT (J30-40XM)
H/S/E1.25-1.75XM, H/S/E2.00XMS (S/H/E25-35XM, 3. Install the retainer assembly onto the rod.
S/H/E40XMS).
4. Install the piston and rod assembly into the cylin-
NOTE: Always use new seals and O-rings. Make sure der. Tighten the retainer to the value shown in
all parts are clean. Lubricate all parts with clean Torque Specifications.
hydraulic oil.
NOTE: After assembly is complete, install the rod
1. Install the piston seal and O-ring(s) onto the pis- end on the cylinder rod. Tighten the capscrew on the
ton. See Figure 2 and Figure 3. Install the piston rod end as specified in Mast section for your specific
onto the cylinder rod. Make sure the piston seal lift truck.
1. CYLINDER SHELL 7. O-RING

2. NUT 8. BACKUP RING
3. PISTON 9. SEAL RING
4. O-RING 10. RETAINER
5. SEAL RING 11. WIPER RING
6. PISTON ROD
Figure 2. Tilt Cylinders for S/H/E/2.00-3.20XM (S/H/E/40-65XM), J2.00-3.00XM (J40-60XM,

J40-60XM 2) (A216), J2.00-3.20XM (J40-60Z) (A416)
3
1. CYLINDER SHELL 6. BACKUP RING

2. RETAINER 7. O-RING
3. ROD 8. NUT
4. WIPER RING 9. PISTON
5. ROD SEAL 10. PISTON SEAL
Figure 3. Tilt Cylinders for H/S/E/J1.25-1.75XM, XMS, XMT (H/S/E/J25-40XM, XMS, XMT)
Tilt Cylinders for H700-800A and Early 3. Install the piston and rod assembly in the shell.
Model H700-920B Install the seals on the retainer. Install the re-
tainer in the shell.
NOTE: Always use new seals and O-rings. Make sure
all parts are clean. Lubricate all parts with clean 4. Install the lock ring in the shell, but do not
hydraulic oil. tighten it. Install the capscrews in the lock ring.
Turn the lock ring until it is even with the end
1. Install the thrust plate on the rod. Install the of the shell. Install the pipe plug in the lock
backup ring and O-ring on the rod. Install the ring and tighten the plug to 34 to 48 N•m (25 to
piston on the rod. Install the piston rings and 35 lbf ft). Tighten the capscrews in the lock ring
seals on the piston. See Figure 4. to 14 to 20 N•m (10 to 15 lbf ft).
2. Install the lock nut on the rod. Tighten the lock 5. Install the rod end on the rod. Tighten the cap-
nut until the thrust plate is tight against the rod. screws on the rod end to 610 N•m (450 lbf ft).
Install the pin in the lock nut and rod if neces-
sary, drill a hole in the rod for the pin. Install
the snap ring to hold the pin in position.
4

2. SNAP RING 13. PISTON ROD
3. LOCK NUT 14. O-RING
4. DOWEL 15. BACKUP RING
5. PISTON RING 16. RETAINER
6. O-RING 17. SEAL RING
7. SEAL RING 18. WIPER RING
8. PISTON RING 19. RETAINER RING
9. PISTON 20. PLUG
10. THRUST PLATE 21. CAPSCREW
11. O-RING
Figure 4. Tilt Cylinders for H700-800A, Early Model H700-920B
INSTALL 3. Connect the hydraulic lines to the tilt cylinder.
1. Use a lifting device to move large tilt cylinders. 4. Operate the tilt cylinders. Check for correct op-
Put the cylinder in the lift truck. Install the an- eration and leakage. Adjust the tilt cylinders
chor pin in the frame. Install the retainer pin or as described in Tilt Cylinder Leak Check and
cotter pin. Tilt Cylinder Stroke and Mast Tilt Angle Adjust-
ment.
2. Install the anchor pin at the mast mount. Install
the retainer pin or cotter pin for the anchor pin.
Tighten the capscrews for the retainer pins.
5
Tilt Cylinders Using Chevron Packing NOTE: After assembly is complete, install the rod
end on the cylinder rod. Tighten the capscrew on the
NOTE: Always use new seals and O-rings. Make rod end as specified in Mast section for your specific
sure all parts are clean. Lubricate all parts with lift truck.
clean hydraulic oil.
NOTE: The following procedure is for the H360-650C

(early model). See Figure 5.

2. NUT 12. RETAINER
3. PISTON HEAD 13. O-RING
4. O-RING 14. BACKUP RING
5. NYLON RING 15. BUSHING
6. PACKING 16. PACKING
7. NYLON RING 17. RETAINER RING
8. PISTON HALF (FLAT) 18. SETSCREW
9. PISTON ROD 19. WIPER RING
10. O-RING
Figure 5. Tilt Cylinders With Chevron Packing (Early Model H360-650C)
6
Install
STEP 1.
Install the O-ring and the backup ring on the bush-
ing. Install the packing in the bushing. The end of
the packing must extend 3 mm (0.125 in.) beyond the
end of the bushing.
1. O-RING
2. BACKUP RING
3. PACKING
4. BUSHING
STEP 2.
Install the O-ring and the backup ring on the re-
tainer. Use your hand to push the bushing into
the retainer. Make sure the O-ring is not damaged
during installation. Install the retainer and bushing
assembly on the cylinder rod.
1. O-RING
2. BACKUP RING
3. BUSHING
STEP 3.
Install the flat piston half on the cylinder rod. Put
the O-ring on the rod halfway between the threads
and the piston half.
1. PACKING
2. PISTON HALF
7
STEP 4.
Install the piston half with the packing on the cylin-
der rod. Make sure the O-ring fits into the piston
groove when the piston half is installed. Install the
piston rod nut. Tighten to the specifications given in
Torque Specifications.
1. O-RING
2. PISTON HALF
3. PISTON HALF WITH PACKING
STEP 5.
Push the piston into the cylinder bore. Push the re-
tainer into the bore. Make sure the O-ring is not dam-
aged.
1. CYLINDER ROD
2. PISTON AND PACKING
3. ROD NUT
8
2100 SRM 103 Tilt Cylinder Leak Check
STEP 6.
Install a new wiper seal in the retainer. Turn the re-
tainer into the cylinder shell until the threads have
started. Push the piston in and out several times to
make sure the alignment is correct.
1. WIPER SEAL
2. RETAINER
STEP 7.
Tighten the retainer to the specifications given in
Torque Specifications. Tighten the setscrew.
1. RETAINER
2. SETSCREW
Tilt Cylinder Leak Check

2. Measure the distance that the rod for tilt cylin-
WARNING der extends from the shell. Check the distance
Never allow anyone under a raised carriage. the rod moves in five or ten minutes. Multiply
Do not put any part of your body in or through the rate in Table 1 by the time of the test and
the lift mechanism unless all parts of the mast compare the numbers.
are completely lowered and the engine is
STOPPED. 3. If the tilt rate is greater than the specifications,
lower the mast and remove the load from the
Do not try to find hydraulic leaks by putting forks. Install a valve between the port at the
your hand on hydraulic components under front of the tilt cylinder and the hydraulic line.
pressure. Hydraulic oil can be injected into Put the load on the forks again. Close the valve.
the body by the pressure. Tilt the mast forward just past the vertical posi-
tion. If the mast continues to tilt slowly forward,
1. Put a capacity load on the forks. Use a safety
the seals on the piston are leaking.
chain to hold the load to the carriage. Raise the
load approximately 2.5 m (8 ft). Put the mast in
a vertical position.
9
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment 2100 SRM 103
4. If the mast does not move, open the gate valve valve can be worn or damaged. Remove the load
and check the movement again. If the mast from the forks when the checks are complete.
moves forward when the gate valve is open,
check for leaks in the hydraulic lines and fit-
tings. If no leaks are found, the main control
Table 1. Movement Rates (Maximum) for Tilt Cylinders
LIFT TRUCK MODEL HYDRAULIC OIL TEMPERATURE/MAST TILT RATE

20 C (68 F) 60 C (140 F)
mm/min in./min mm/min in./min
A1.00-1.50XL (A20-30XL) 1.3 0.05 9.1 0.50
E1.25-5.50XL,XM (E25-120XL) 0.8 0.03 5.0 0.20
J1.60-2.00XMT (J30-40XM) 0.8 0.03 5.0 0.20
E2.00-3.20XM (E40-65XM) 0.8 0.03 5.0 0.20
J2.00-3.20XM (J40-60XM, J40-60XM 2) 0.8 0.03 5.0 0.20
(A216)
J2.00-3.20XM (J40-60Z) (A416) 0.8 0.03 5.0 0.20
H1.25-1.75XL (H25-35XL) 0.8 0.03 5.0 0.20
S/H1.50-1.75XM, S/H2.00XMS 0.8 0.03 5.0 0.20
(S/H25-35XM, S/H40XMS)
H2.00-3.00XL (H40-60XL) 1.1 0.04 7.3 0.30
S/H2.00-3.20XM (S/H40-65XM) 1.0 0.04 6.8 0.30
H3.50-7.00XL (H70-155XL) 1.3 0.05 8.9 0.34
H8.00-16.00XL (H165-360XL) 1.8 0.07 11.7 0.05
H8.00-16.00XM (H170-360HD) 1.8 0.07 11.7 0.05
H20.00-32.00F (H440-700F/FS) 1.3 0.05 3.8 0.15
H36.00-48.00C (H800-1050C) 1.3 0.05 3.8 0.15
J2.00-3.00XL (J40-60XL) 0.8 0.03 5.0 0.20
J25-35A,B 1.3 0.05 3.8 0.15
S1.25-5.50XL (S25-120XL) 0.8 0.03 5.0 0.20
S6.00-7.00XL (S135-155XL) 1.2 0.05 8.2 0.32
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment

Adjust the tilt cylinders as described in the section Mast.
10
2100 SRM 103 Torque Specifications
Torque Specifications
PISTON ROD NUT H7.00-12.50H (H150-275H)
447 to 475 N•m (330 to 350 lbf ft)
E1.25-1.75XL (E25-35XL)
163 to 190 N•m (120 to 140 lbf ft) H8.00-12.00XL (H165-280XL)
950 to 985 N•m (700 to 725 lbf ft)
J1.60-2.00XMT (J30-40XM)
1105 to 1140 N•m (815 to 840 lbf ft)
E2.00-3.00XL (E40-60XL)
320 to 400 N•m (236 to 295 lbf ft) H16.00-30.00C (H360-650C) - Early
1356 to 1492 N•m (1000 to 1100 lbf ft)
E2.00-3.20XM (E40-65XM)
150 N•m (110 lbf ft) H16.00-30.00C (H360-650C) - Late
1500 to 1600 N•m (1107 to 1181 lbf ft)
J2.00-3.20XM (J40-60XM, J40-60XM 2) (A216)
150 N•m (110 lbf ft) H17.00-32.00C (H370-700C)
1500 to 1600 N•m (1107 to 1181 lbf ft)
J2.00-3.20XM (J40-60Z) (A416)
150 N•m (110 lbf ft) H20.00-32.00F (H440-700F/FS)
1500 to 1600 N•m (1107 to 1181 lbf ft)
E20-30B
244 to 271 N•m (180 to 200 lbf ft) H32.00-44.00B (H700-920B) - Late
1500 to 1600 N•m (1107 to 1181 lbf ft)
E30-60B, E30-60AC
407 to 475 N•m (300 to 350 lbf ft) H36.00-48.00C (H800-1050C)
1500 to 1600 N•m (1107 to 1181 lbf ft)
E3.50-5.50XL (E70-120XL)
400 to 440 N•m (295 to 325 lbf ft) H60-90C
407 to 447 N•m (300 to 330 lbf ft)
E60-100B
407 to 440 N•m (300 to 325 lbf ft) H60-110E
400 to 440 N•m (295 to 325 lbf ft)
H1.25-1.75XL (H25-35XL)
163 to 190 N•m (120 to 140 lbf ft) H110-150F
678 to 746 N•m (500 to 550 lbf ft)
H/E1.50-1.75XM, H/E2.00XMS
(H/E25-35XM, H/E40XMS) H300A
163 to 190 N•m (120 to 140 lbf ft) 678 to 746 N•m (500 to 550 lbf ft)
H20-30E H300-350B
H2.00-3.00XL (H40-60XL) H360-620B

S/H2.00-3.20XM (S/H40-65XM) H700-800A, H700-920B - Early See Text

150 N•m (110 lbf ft)
J2.00-3.00XL (J40-60XL)
H30-60H, H40-60J 320 to 400 N•m (236 to 295 lbf ft)
244 to 271 N•m (180 to 200 lbf ft)
J25-35A
H3.50-5.00XL (H70-110XL) 244 to 271 N•m (180 to 200 lbf ft)
400 to 440 N•m (295 to 325 lbf ft)
J25-35B
H6.00-7.00XL (H135-155XL) 320 to 400 N•m (236 to 295 lbf ft)
407 to 440 N•m (300 to 325 lbf ft)
11
Torque Specifications 2100 SRM 103
J40-60A, J50-60AS E20-30B

P40-50A, P60-80A E30-60B, E30-60AC

P7.00-8.00B (P150-200B) E3.50-5.50XL (E70-120XL)

S20-30A E60-100B
S30-60E, S40-50F H1.25-1.75XL (H25-35XL)

S40-50C H/E1.50-1.75XM, H/E2.00XMS

224 to 271 N•m (165 to 200 lbf ft) (H/E25-35XM, H/E40XMS)
163 to 176 N•m (120 to 130 lbf ft)
S1.25-1.75XL (S25-35XL)
163 to 190 N•m (120 to 140 lbf ft) H20-30E
203 to 271 N•m (150 to 200 lbf ft)
S25-35XM, S40XMS
169 to 237 N•m (125 to 175 lbf ft)
S2.00-3.00XL (S40-60XL)
320 to 400 N•m (236 to 295 lbf ft) S/H2.00-3.20XM (S/H40-65XM)
170 to 237 N•m (125 to 175 lbf ft)
S3.00-5.50E (S60-120E)
407 to 440 N•m (300 to 325 lbf ft) H30-60H, H40-60J
407 to 475 N•m (300 to 350 lbf ft)
S3.50-5.50XL (S70-120XL)
400 to 500 N•m (295 to 369 lbf ft)
S5.50-7.00A (S125-150A)
542 to 610 N•m (400 to 450 lbf ft)
S6.00-7.00XL (S135-155XL)
407 to 440 N•m (300 to 325 lbf ft) H7.00-12.50H (H150-275H)
475 to 542 N•m (350 to 400 lbf ft)
RETAINER
H8.00-12.00XL (H165-280XL)
E1.25-1.75XL (E25-35XL) 542 to 610 N•m (400 to 450 lbf ft)
169 to 237 N•m (125 to 175 lbf ft)
H13.00-16.00XL (H300-360XL)
J1.60-2.00XMT (J30-40XM) 610 to 675 N•m (450 to 500 lbf ft)
163 to 176 N•m (120 to 130 lbf ft)
H16.00-30.00C (H360-650C) - Early
E2.00-3.00XL (E40-60XL) 542 to 610 N•m (400 to 450 lbf ft)
400 to 500 N•m (295 to 369 lbf ft)
H16.00-30.00C (H360-650C) - Late
E2.00-3.20XM (E40-65XM) 450 to 550 N•m (332 to 406 lbf ft)
170 to 237 N•m (125 to 175 lbf ft)
H17.00-32.00C (H370-700C)
J2.00-3.20XM (J40-60XM, J40-60XM 2) (A216) 450 to 550 N•m (332 to 406 lbf ft)
170 to 237 N•m (125 to 175 lbf ft)
H20.00-32.00F (H440-700F/FS)
J2.00-3.20XM (J40-60Z) (A416) 450 to 550 N•m (332 to 406 lbf ft)
170 to 237 N•m (125 to 175 lbf ft)
12
H32.00-44.00B (H700-920B) - Late P40-50A, P60-80A

H36.00-48.00C (H800-1050C) P7.00-8.00B (P150-200B)

H60-90C S20-30A
H60-110E S30-60E, S40-50F

H110-150F S40-50C
H300A S1.25-1.75XL (S25-35XL)

169 to 237 N•m (125 to 175 lbf ft)
H300-350B
475 to 542 N•m (350 to 400 lbf ft) S25-35XM, S40XMS
163 to 176 N•m (120 to 130 lbf ft)
H360-620B
542 to 610 N•m (400 to 450 lbf ft) S2.00-3.00XL (S40-60XL)
400 to 500 N•m (295 to 370 lbf ft)
H700-800A, H700-920B - Early See text
S3.00-5.50E (S60-120E)
J2.00-3.00XL (J40-60XL) 576 to 644 N•m (425 to 475 lbf ft)
400 to 500 N•m (295 to 369 lbf ft)
S3.50-5.50XL (S70-120XL)
J25-35A 400 to 500 N•m (295 to 370 lbf ft)
407 to 475 N•m (300 to 350 lbf ft)
S5.50-7.00A (S125-150A)
J25-35B 176 to 244 N•m (130 to 180 lbf ft)
400 to 500 N•m (295 to 369 lbf ft)
S6.00-7.00XL (S135-155XL)
J40-60A, J50-60AS 542 to 610 N•m (400 to 450 lbf ft)
475 to 542 N•m (350 to 400 lbf ft)
13
Troubleshooting
Tilt cylinder movement is Air is in the hydraulic system. Remove air from hydraulic system.
slow or not smooth.
The hydraulic pump is worn or dam- Repair or replace hydraulic pump.

aged.
Restriction in the hydraulic lines. Repair hydraulic lines.
Seals in tilt cylinder are damaged. Replace seals and inspect cylinder
bore for damage.
Tilt cylinders have internal damage. Repair or replace cylinder.
Load is greater than capacity. Reduce load.
Pressure relief valve(s) is not ad- Repair or adjust relief valve(s).

justed correctly or is damaged.
Spool is not fully extended or re- Adjust linkage to spool.

tracted.
Tilt control spool is damaged. Repair control valve.
The tilt cylinders permit the There are leaks in the hydraulic Tighten fittings or repair leaks.
mast to move when the Tilt lines.
control lever is in the Neu-
tral position.
Seals in tilt cylinder are damaged. Replace seals and inspect cylinder
bore for damage.
Tilt cylinders have internal damage. Repair or replace cylinder.
Tilt control spool is damaged. Repair control valve.
14
2100 SRM 103 10/03 (3/03)(9/00)(6/96)(11/95)(5/95)(1/95)(11/94)(3/94)(9/93)(4/93) Printed in United Kingdom

ELECTRICAL SYSTEM
J1.6-2.0XMT (J30-40ZT) [J160]
PART NO. 1554634 2200 SRM 1078

SAFETY PRECAUTIONS

trucks.
nance section.
manual:
WARNING
CAUTION
Electrical System Table of Contents
TABLE OF CONTENTS
Introduction........................................................................................................................................................ 1
General ........................................................................................................................................................... 1
Emissions ....................................................................................................................................................... 3
Electromagnetic Interference ................................................................................................................... 3
Motor Controllers............................................................................................................................................... 3
Controllers ..................................................................................................................................................... 3
Remove....................................................................................................................................................... 3
Install ......................................................................................................................................................... 4
Hydraulics Contactor .................................................................................................................................... 5
Remove....................................................................................................................................................... 5
Disassemble ............................................................................................................................................... 5
Assemble .................................................................................................................................................... 5
Install ......................................................................................................................................................... 5
Contactor Panel.................................................................................................................................................. 6
Main Contactor .............................................................................................................................................. 6
Remove....................................................................................................................................................... 6
Disassemble ............................................................................................................................................... 7
Assemble .................................................................................................................................................... 7
Install ......................................................................................................................................................... 8
Contactor Coil............................................................................................................................................ 8
Contactor Tips ........................................................................................................................................... 8
Fuses .............................................................................................................................................................. 8
Display Units ..................................................................................................................................................... 9
Features ......................................................................................................................................................... 9
Replace ........................................................................................................................................................... 10
Key Switch.......................................................................................................................................................... 10
Replace ........................................................................................................................................................... 10
Directional Controls........................................................................................................................................... 12
Directional Control Switches ........................................................................................................................ 12
Accelerator Switches and Pedal Assembly................................................................................................... 13
Install ............................................................................................................................................................. 13
Calibrate......................................................................................................................................................... 16
MONOTROL™ Directional Control ............................................................................................................. 16
Brakes................................................................................................................................................................. 18
Brake Switch.................................................................................................................................................. 18
Adjust or Replace ...................................................................................................................................... 18
Master Cylinder Indicator............................................................................................................................. 18
Parking Brake Disengage ............................................................................................................................. 19
Override Mode ........................................................................................................................................... 19
Horn Components and Steering Encoder ......................................................................................................... 20
Horn Components .......................................................................................................................................... 20
Horn ........................................................................................................................................................... 20
Horn Button and Contacts........................................................................................................................ 21
Steering Encoder ........................................................................................................................................... 21
Hood and Seat Switches .................................................................................................................................... 22
Hood Position Switches ................................................................................................................................. 22
Seat Switch .................................................................................................................................................... 22
Steer Angle Potentiometer ................................................................................................................................ 22
General ........................................................................................................................................................... 22
Operation ....................................................................................................................................................... 22

Table of Contents Electrical System
TABLE OF CONTENTS (Continued)

Example ..................................................................................................................................................... 23
Position Steer Tire for Straight Travel......................................................................................................... 23
Install ............................................................................................................................................................. 24
Set Potentiometer to Midpoint ................................................................................................................. 24
Install to Steer Axle .................................................................................................................................. 24
Calibrate .................................................................................................................................................... 25
Test ................................................................................................................................................................. 25
Wiring Harness .................................................................................................................................................. 26
J1.6-2.0XMT (J30-40ZT) [J160]
ii
Introduction
GENERAL
This section includes removal, disassembly, checks,
adjustments, assembly, installation, and trou-
bleshooting procedures for the electrical system
components on these models. Components covered
in other sections, such as motors and industrial
batteries, are not included in this section.
See the section AC Motor Controllers/Display

Panel, Description, Checks, Adjustments, and
Troubleshooting 2200 SRM 1087 for additional
information on the controller and for information on
troubleshooting fault codes, adjusting parameters,
and testing the controller.
A. LEFT SIDE
See the section AC Motor Repair 620 SRM 1053 for B. RIGHT SIDE
general information on AC motors. C. FORWARD TRAVEL
See the section DC Motor Maintenance 620 SRM Figure 1. Truck Orientation
294 for general information on DC motors.
See the section Industrial Battery 2240 SRM 1 for
information on battery maintenance.
WARNING
See the section Electro-Hydraulic Control Valve Do not make repairs or adjustments unless you
2000 SRM 1086 for information and service proce- are properly trained and authorized to do so.
dures on the electro-hydraulic valve option and its Repairs and adjustments that are not correct
components. can create dangerous operating conditions. Do
not operate a lift truck that needs repairs. Re-
See the section Periodic Maintenance 8000 SRM port the need for repairs to your supervisor im-
1079 for regular maintenance schedules and proce- mediately. If repair is necessary, attach a DO
dures. NOT OPERATE tag on the steering wheel. Re-
move the key from the key switch.
See the section Diagrams 8000 SRM 1081 for the
wiring diagrams and schematics.
WARNING
Throughout this section, forward will refer to travel Disconnect the battery before opening the elec-
in the direction of the forks and left and right are trical compartment cover or inspecting or re-
determined by an operator sitting in the seat facing pairing the electrical system. If a tool causes
forward. See Figure 1. a short circuit, the high current flow from the
battery can cause personal injury or property
damage.
WARNING
1
WARNING
Block the lift truck to prevent unexpected
movement before performing any tests or ad-
justments.
WARNING
been disconnected.
CAUTION
To avoid controller damage, always disconnect 1. POSITIVE CONNECTION (BT+)
the battery, discharge the capacitor(s), and 2. NEGATIVE CONNECTION (B )
never put power to the controller while any 3. INSULATED JUMPER WIRES
power wires are disconnected. Never short 4. 200-OHM, 2-WATT RESISTOR
the battery. Make sure to use proper proce- Figure 2. Discharging the Capacitors
dure when servicing the controller.

the battery. Block load wheels to prevent lift
truck from moving.
2. Open the electrical compartment located at the

rear of the truck.
a. Remove the two screws securing the electri-

cal compartment door.
b. Tilt the door back on its hinges to open the

compartment.


controller’s BT+ and B terminals for 10 seconds 1. POSITIVE CONNECTION (BT+)
using insulated jumper wires. See Figure 2. 2. NEGATIVE CONNECTION (B )
4. On the premium controller, also connect the 200- 4. 200-OHM, 2-WATT RESISTOR
ohm, 2-watt resistor across the controller’s P+
and B terminals for 10 seconds using insulated Figure 3. Discharging the Capacitors

2
2200 SRM 1078 Motor Controllers
EMISSIONS voltage. It stores surges of electricity and gradu-

ally releases the stored energy over a period of time.
Electromagnetic Interference These components are not serviced unless physically
damaged. Replace any damaged EMI reduction de-
Electromagnetic interference (EMI), also referred to vices immediately to maintain acceptable EMI emis-
as radio-frequency interference (RFI), is the term sion levels.
given to any unwanted electromagnetic disturbances
affecting the performance of useful electronic sig-
nals. The electrical system of the lift truck is capable
of producing EMI emissions during normal opera-
tion. Several EMI reduction devices are placed near
the transistor controller to reduce electromagnetic
emissions. These devices do not affect the perfor-
mance of the lift truck and help reduce disruptions
to communications devices, computers, and other
electronic devices.
EMI reduction devices on these models include a ca-

pacitor on premium controllers and a series of fer-
rites installed standard on the transistor controller
power cables of all controllers. On models with tran-
sistor hydraulics (premium controller only), the ca-
pacitor is installed between the BPF+ and P termi-
nals (see Figure 4) on the controller and functions
as an EMI reduction device. Ferrites are washer-
shaped, solid metallic components installed on the
1. PREMIUM CONTROLLER
power cables. Refer to Figure 5 or Figure 6. They 2. CAPACITOR POSITIVE (BPF+)
reduce EMI by blocking some of the emissions cre- 3. CAPACITOR NEGATIVE (P-)
ated by the power cables. The capacitor (premium
controller only) reduces EMI by regulating spikes in Figure 4. Capacitor Placement
Motor Controllers
The motor controller assembly is mounted to the CONTROLLERS
inside of electrical compartment door. The con-
troller is factory mounted to an aluminum heat sink. Remove
The controller and heat sink assembly is mounted
against heat dispersal vanes in the electrical com- Certain repairs may not require the removal of all
partment door with socket-head screws. A thin layer components. Perform only the procedures necessary
of thermal grease maximizes heat transfer between to complete the repairs. For the following proce-
the heat sink and the electrical compartment door. dures, refer to Figure 5 or Figure 6.
The standard controller controls the power supply 1. Turn the key switch to the OFF position and
and feedback from the traction motors. A contactor is disconnect the battery. Place blocks in front of
mounted beside the standard controller on the heat and behind the tires to prevent unexpected move-
sink, which controls current flow to the lift pump mo- ment.
tor. The premium controller manages power for both
the traction motors and the lift pump motor; there is
rear of the truck.
no need for a lift motor contactor on this model.
3
Motor Controllers 2200 SRM 1078
CAUTION
Do not remove the controller from the heat
sink plate. The controller is factory set and
mounted to the heat sink plate. ONLY remove
the controller and heat sink as an assembly.
6. Remove the socket-head screws retaining the

controller and heat sink assembly to the electri-
1. CONTROLLER
2. HEAT SINK
3. HYDRAULIC CONTACTOR
4. FERRITES
Figure 5. Controller With Contactor Hydraulics

(Standard)

compartment.
CAUTION
Be sure to remove the resistor from the con-
troller before reconnecting the battery connec-
tor.
1. CONTROLLER
3. Discharge the capacitors. See Discharging the 2. HEAT SINK
Capacitors in this section. 3. FERRITES
4. Tag and disconnect the wiring and cables from Figure 6. Controller With Transistor
the controller and hydraulic contactor if so Hydraulics (Premium)
equipped. It may be helpful to make a sketch
of the routing of the wiring and cables for assis- Install
tance during reassembly.
5. Remove the hydraulic contactor (contactor hy- CAUTION

draulic models), if necessary. See Hydraulics The area where the controller mounts on the
Contactor. heat sink must be clean, free of paint and rust,
and completely covered with a thin, level coat
of electrical grease before the controller is in-
stalled.
4
2200 SRM 1078 Motor Controllers
1. Install the heat sink to the inside of the electrical Disassemble

compartment door and secure using socket-head
screws, if removed. 1. Remove contactor from heat sink. See Remove.
2. Clean the heat sink thoroughly of paint, dirt, 2. Remove screws that fasten the top cover to the
and rust. Apply a thin, level coat of electrical coil and frame.
grease to the heat sink completely covering the
3. Remove cover, moving contact, and return
area where the controller is to be mounted.
spring.
3. Install the controller to the heat sink using
4. Remove capscrews, washers, and nuts that make
screws as removed.
up the fixed contactor tips from the top cover if
4. Install the hydraulic contactor (contactor hy- the contacts must be replaced. See Contactor
draulic models), if removed. See Hydraulics Tips in this section.
Contactor.
5. If the coil will be replaced, remove coil frame and
5. Connect cables and wiring to controller as re- remove end cap from frame. For information on
moved. Apply a light coat of electrical grease to testing the contactor coil, see Contactor Coil in
each piece of the electrical connections during as- this section.
sembly. Torque all cable connections to 13 N•m
(115 lbf in). Assemble
1. Install new coil on frame and install end cap, if
HYDRAULICS CONTACTOR
removed.
The hydraulic contactor is mounted on the heat sink
2. Install moving contact and return spring.
beside the standard controller. See Figure 5.
3. Install capscrews, washers, and nuts, which
Remove make up the fixed contactor tips, to the top
cover.
1. Turn the key switch to the OFF position and
disconnect the battery. Place blocks in front of NOTE: Check that the moving contactor and springs
and behind the tires to prevent unexpected move- move freely without binding.
ment.
4. Install cover to coil and frame using screws.
rear of the truck. 5. Install contactor assembly onto heat sink. See
Install.
cal compartment door closed. Install
b. Tilt the door back on its hinges to open the 1. Install the lift contactor to the heat sink using
compartment. screws as removed.
2. Connect cables and wiring to the lift contactor as

CAUTION removed.
Be sure to remove the resistor from the con-
troller before reconnecting the battery connec- 3. Close the electrical compartment door and secure
tor. using two screws.
3. Discharge the capacitors. See Discharging the 4. Remove blocks from wheels, connect the battery,
Capacitors in this section. and test for proper operation.
4. Tag and disconnect the wiring and cables from

the contactor.
5. Remove the screws securing the lift contactor to

the heat sink.
5
Contactor Panel 2200 SRM 1078
Contactor Panel
MAIN CONTACTOR
WARNING
The capacitor in the transistor controller can Remove
disconnected. Discharge the capacitor before WARNING
inspecting or repairing any component in the
electrical compartment to prevent personal in-
jury and damage to the electrical system. Al-
ways wear safety glasses. 1. Turn the key switch to the OFF position and dis-
See Discharging the Capacitors, in this section, for
information on how to properly discharge the capac- 2. Open the electrical compartment located at the
itors. The contactor panel is located in the electrical rear of the truck.
compartment. See Figure 7.
cal compartment door closed.

compartment.
1. CONTACTOR PANEL 8. FUSE (FU13)

2. MOUNTING HOLE 9. FUSE (FU14)
3. LABELS 10. FUSE (FU15)
4. ENCLOSURE (EE) 11. MAIN CONTACTOR
5. SCREWS (EE) 12. FUSE (FU3)
6. FUSE (FU11) 13. FUSE (FU2)
7. FUSE (FU12) (CONTACTOR HYDRAULICS)
Figure 7. Contactor Panel
6
2200 SRM 1078 Contactor Panel
3. Discharge the capacitors. See Discharging the

Capacitors.
4. If the lift truck has an EE rating, remove cover

of the contactor box for access to the contactor
terminals.
5. Tag and disconnect the wires and cables from the

contactor assembly.
6. Remove two mounting screws securing contactor

assembly to the contactor panel and remove the
contactor assembly.
Disassemble
1. Remove contactor assembly from the contactor

panel. Refer to Remove.
2. Remove screws (4) that fasten the top cover to the

coil and frame.
3. Remove cover, moving contact (2), and return

spring.
4. Remove capscrews, washers, and nuts that make

up the fixed contactor tips (1) from the top cover.
5. If a coil will be replaced, remove coil frame and

remove end cap from frame.
6. Remove coil from frame.
Assemble
1. Install new coil on frame and install end cap, if

removed.
2. Install moving contact (2) and return spring.
3. Install capscrews, washers, and nuts that make

up the fixed contactor tips (1) to the top cover.
NOTE: Check that the moving contactor and springs

move freely without binding. 1. FIXED CONTACT 5. RETURN SPRING
2. MOVING CONTACT 6. COIL AND FRAME
4. Install cover to coil and frame using screws (4). 3. TOP COVER 7. END CAP
4. SCREW
Figure 8. Main Contactor
7
Contactor Panel 2200 SRM 1078
Install FUSES
1. Position contactor assembly in place and install
two mounting screws securing the contactor to
WARNING
the contactor panel. DO NOT short across the motor controller ter-
2. Install wires and cables to the contactor assem-
bly as removed. 1. Turn the key switch to the OFF position and dis-
3. Install cover of contactor box on EE units.
4. Connect the battery, turn the key switch to the rear of the truck.
ON position, and test for proper operation.
5. Close the electrical compartment door and secure cal compartment door closed.
using two screws.
Contactor Coil compartment.
Test the contactor coil. 3. Discharge the capacitors. See Discharging the
Capacitors.
Tag and disconnect coil wires. Check the coil using
an ohmmeter to measure the resistance. Record the 4. Check the fuses. The condition of fuses can nor-
highest resistance indication. The coil should read 33 mally be checked visually, although some fuses
ohms ±10%. Replace coil with new one if resistance do not change in appearance and must be re-
readings are outside the specified range. Make sure moved and checked with an ohmmeter. Replace
coil wires are connected to the proper terminals. See all bad fuses. Check to determine the cause of
Figure 8. the fuse failure before replacing the fuse.
5. Connect the battery and turn the key switch to

Contactor Tips
the ON position. Check for proper operation.
CAUTION 6. Secure the rear compartment door closed.

All contactor tips must be replaced at the same Fuses Circuit Rating
time if any are replaced.
FU-2 Hydraulic Motor 500A
NOTE: If both the contactor tips and the coil will be (Contactor Hydraulics)
replaced, replace the entire contactor assembly as de-
scribed in Remove and Install. FU-3 Steer Motor 60A
FU-11 Light 10A
The contactor tips are made of special silver alloy.
The contacts will look black and rough from normal FU-12 Horn and Display 5A
operation. This condition is normal and requires no FU-13 Valve Drivers and Lever 5A
service. Cleaning is not necessary. DO NOT USE Controller
A FILE ON THE CONTACTS. DO NOT LUBRI-
CATE THE CONTACTS. Replace contacts when FU-14 Motor Controllers 5A
the silver alloy is worn away to the base support FU-15 Auxiliary 20A
metal. Replace contactor tips at the same time.
Perform only the procedures necessary to complete
the repairs. See Figure 8.
8
2200 SRM 1078 Display Units
Display Units
FEATURES These features are shown in Figure 9. Since the
indicators are for common features, these indica-
The following features are part of both the Standard tors are the same on the Premium Display Unit.
and Premium Display Units: For more information on the standard and pre-
• LED (Light Emitting Diode) Symbol Indicators mium display units and their features, see AC
• LCD (Liquid Crystal Display) Screen Motor Controllers/Display Panel, Description,
• Hourmeter Indicator Checks, Adjustments, and Troubleshooting
• Service Indicator 2200 SRM 1087.
• Battery Discharge Indicator
• Master Cylinder Indicator
• Parking Brake Indicator
• Seat Belt Indicator
1. HOURMETER 7. BUTTON 5
2. SERVICE INDICATOR 8. BUTTON 4
3. BATTERY INDICATOR 9. BUTTON 3
4. MASTER CYLINDER INDICATOR 10. BUTTON 2
5. PARKING BRAKE INDICATOR 11. BUTTON 1
6. SEAT BELT INDICATOR 12. STAR BUTTON
Figure 9. Standard and Premium Display Units
9
Key Switch 2200 SRM 1078
REPLACE 4. Lift the display unit from the top of the instru-
ment panel (dash).
WARNING 5. Install the new display unit into the instrument
Before replacing the display, fully lower all panel (dash) from the top.
parts of the mast and tilt it forward until the
tips of the forks touch the ground. This action 6. Secure display unit in place using four finger
will prevent the mast from lowering suddenly nuts.
if the control lever is accidentally moved.
7. Install the connectors to the bottom of the display
Always disconnect the battery, remove the key, unit as removed.
and discharge the capacitor before replacing
the display. 8. Connect the battery and turn the key switch to
the ON position.
Never have any metal on your finger, arms, or
neck. Metal items can accidentally make an 9. Test the display unit for proper operation before
electrical connection and cause an injury. returning the lift truck to service.
CAUTION
A short circuit and damage can occur if wires
are not installed correctly. Make sure wire con-
nectors do not touch other power sources or
grounds. Make sure the wires are not pulled
tight or pinched. Route the wires to prevent
rubbing, chafing, or pinch points that can dam-
age the wires.
The display unit is located in the instrument panel

(dash) and has no serviceable parts. If malfunction-
ing, the unit must be replaced. See Figure 10.
1. Lower the mast, turn the key switch to the OFF

position, and disconnect the battery.
1. CONNECTOR
2. Disconnect the connectors from the bottom of the 2. FINGER NUTS
display unit. 3. CONNECTOR
3. Remove four finger nuts retaining the display Figure 10. Display Unit Mounting
unit.
Key Switch
REPLACE NOTE: Make a note of proper switch orientation for
reference during installation.
1. Turn the key switch to the OFF position and re-
move the key. Disconnect the battery connector. 4. Remove the key switch retaining nut from the
outside of the lower cover. See Figure 12.
2. Disassemble the steering column covers by re-
moving six screws securing the covers together 5. Remove the key switch from the lower cover and
and two screws securing the latch release. Care- remove the static ground strap from the switch.
fully separate the covers and collect all plugs.
See Figure 11. 6. Install the static ground strap to the new key
switch and position the switch into the lower
3. Tag and disconnect the wiring from the key cover.
switch.
10
2200 SRM 1078 Key Switch
1. STEERING KNOB 8. LATCH RELEASE

2. HORN BUTTON 9. SCREW
3. STEERING WHEEL 10. LOWER COVER
4. UPPER COVER 11. SCREW
5. COLUMN BRACKET 12. PLUG
6. STATIC GROUND STRAP 13. PLUG
7. KEY SWITCH
Figure 11. Key Switch Replacement
NOTE: Make sure static ground strap is aligned with 9. Install the covers by assembling each half around
screw hole in the cover. the steering column and installing six screws.
7. Install the key switch retaining nut to threads of 10. Install latch release and secure using two screws.
the key switch. Position switch and static ground
strap as removed and tighten retaining nut. 11. Connect the battery connector, insert the key into
the key switch, and turn to the ON position. Test
8. Install wiring to the key switch as removed. for proper operation.
11
Directional Controls 2200 SRM 1078
Legend for Figure 12

1. KEY SWITCH
2. RETAINING NUT
3. KEY
Figure 12. Key Switch
Directional Controls
DIRECTIONAL CONTROL SWITCHES 5. Install new switches and adjust so switch opens
and closes properly with movement of the direc-
The directional control lever is mounted on the left tional control lever.
hand side of the steering column. This lever is
attached to linkages, which activate the directional 6. Install wiring to switches as removed.
control switches located inside the steering column.
These switches are responsible for communicating
to the controller which direction to turn the traction
motor.
See Figure 13 for the following procedures.

connect the battery. Place blocks in front and be-
hind the drive tires to prevent unexpected move-
ment.
2. Remove the steering column covers. See Steer-

ing System 1600 SRM 1075, Remove.
3. Tag and disconnect wiring from switches.
4. Remove the screws securing the directional con-

trol switches to the switch plate.
CAUTION 1. DIRECTIONAL CONTROL LEVER

DO NOT overtighten screws securing direc- 2. DIRECTIONAL CONTROL SWITCHES
tional control switches to the switch plate. 3. CONNECTORS
Figure 13. Directional Control Switches
12
2200 SRM 1078 Directional Controls
7. Install the steering column covers and secure us- 6. Apply power and install a voltmeter to the throt-
ing six screws as removed. See Steering Sys- tle position sensor:
tem 1600 SRM 1075, Install.
a. Connect pin A of the throttle position sensor
8. Check for proper operation before returning to connector to pin A of the main wiring harness
service. connector using a jumper wire.
ACCELERATOR SWITCHES AND PEDAL b. Connect pin C of the throttle position sensor
ASSEMBLY connector to pin C of the main wiring harness
connector using a jumper wire.
The accelerator pedal is used to control the speed and
acceleration of the traction motors. The pedal is foot c. Connect the battery and turn the key switch
controlled and is spring returned to its up position. to the ON position.
A neutral switch mounted on the mounting bracket d. Connect one voltmeter lead to the jumper
monitors when the pedal is in the neutral position. wire at pin C.
When the pedal is depressed, a throttle position sen-
sor (potentiometer), mounted on the bracket below e. Use the other voltmeter lead to probe pin B
the neutral switch, communicates the position of the of the throttle position sensor connector.
pedal to the controller. The controller then signals
the traction motors to accelerate accordingly. 7. Adjust the switches:
INSTALL a. Adjust the throttle position sensor so that the

voltmeter reads 3.80 to 3.95 Volts with the
accelerator pedal in the full up position.
WARNING
Installing and adjusting the throttle position b. Tighten the screws to hold the throttle po-
sensor can cause the lift truck to move unex- sition sensor stationary. DO NOT OVER-
pectedly. DO NOT attempt to install the sen- TIGHTEN.
sor until the drive tires have been suspended
above the floor. c. Position the neutral switch so that the actua-
tor is depressed just enough to click the con-
1. Turn the key switch to the OFF position and dis- tacts inside the switch when the accelerator
connect the battery. pedal is in the full upright position.
2. Position the lift truck on blocks so that the drive d. Tighten the screws to hold the neutral switch
tires are suspended above the floor. stationary. DO NOT OVERTIGHTEN.
3. Mount neutral switch with isolator pad to the ac- e. Depress the accelerator pedal just until
celerator bracket loosely using two screws, lock- the neutral switch contacts click again and
washers, washers, and nuts. See Figure 14. HOLD.
NOTE: This application requires the neutral switch f. Verify that the voltmeter attached to the
to be wired normally closed (NC). Connect wiring to throttle position sensor reads 3.64 to 3.69
the normally closed terminal (NC) and the neutral Volts with the accelerator in this position.
terminal on the neutral switch. Adjust as necessary.
4. Connect wiring to the neutral switch as removed. g. Fully depress the accelerator pedal to the
lower stop and HOLD.
NOTE: Make sure the throttle position sensor arm is
installed to the pin on the accelerator pedal at instal- h. Verify that the voltmeter reads 0.54 to 0.36
lation. Refer to Figure 15. Volts with the accelerator in this position.
Adjust as necessary.
5. Install the throttle position sensor loosely to the
accelerator bracket using two screws, washers, i. Torque neutral switch and throttle position
lockwashers, and nuts. sensor screws to 2.2 N•m (19 lbf in).
13
1. CAPSCREW 9. SCREW
2. LOCKWASHER 10. NUT
3. WASHER 11. SCREW
4. PEDAL STOP 12. WASHER
5. NEUTRAL SWITCH 13. LOCKWASHER
6. INSULATOR 14. NUT
7. WASHER 15. THROTTLE POSITION SENSOR
8. LOCKWASHER 16. ACCELERATOR BRACKET
Figure 14. Accelerator Switches Installation
14
1. NEUTRAL SWITCH 8. BUSHING

2. THROTTLE POSITION SENSOR 9. WASHER
3. PEDAL STOPS 10. LOCKWASHER
4. NUT 11. CAPSCREW
5. NUT 12. CAPSCREW
6. LOCKWASHER 13. SPRING
7. PEDAL 14. PIN
Figure 15. Accelerator Switches
15
8. Turn the key switch to the OFF position and dis- direction of travel is selected by pressing switches
connect the battery. on the left or right side of the accelerator pedal.
9. Remove the voltmeter and jumper wires from the 8. Move the directional control lever to the forward
connectors. position if so equipped.
10. Install the connector to the throttle position sen- 9. Slowly depress the accelerator pedal until com-
sor as removed. pletely depressed and HOLD for one second to
set the forward throttle value.
11. Install the floor plates and floormat.
10. Move the directional control lever to the reverse
12. Calibrate the throttle position sensor to the con- position if so equipped.
troller. See Calibrate.
11. Slowly depress the accelerator pedal until com-
CALIBRATE pletely depressed and HOLD for one second to
set the reverse throttle value.
1. From the seat, turn the key switch to the ON
position. NOTE: The new calibration values may be canceled
at any time until the Star button is pressed. Press
2. Press the Star key on the display panel two times button 3 to cancel calibration mode.
to display the password login screen.
12. Press the Star button to save values. Slowly re-
3. Enter the service password. lease the pedal and move the directional control
lever to the neutral position.
4. Scroll up or down to “Setup” using button 1 and
button 2 on the display panel. 13. Press button 3 four times to completely back out
of service mode.
5. Press button 4. “Traction Settings” will display.
14. Test the truck for proper acceleration in a safe,
6. Press button 4. “Throttle Calibration” will dis-
unobstructed area.
play.
7. Press button 4 again to initiate calibration mode. MONOTROL™ DIRECTIONAL CONTROL

An optional feature is the MONOTROL™ Direc-
WARNING tional Control pedal. This allows hand-free direc-
The truck should not accelerate in either ditional and speed control. Switches on the left and
rection when the truck is in calibration mode. right side of the MONOTROL™ Directional Control
SLOWLY depress the accelerator and check pedal signal the controller which direction to travel.
that the truck does not move. NEVER perform Refer to Install. The speed and acceleration rate is
calibration around equipment or personnel in determined by how far the pedal is depressed, just
case of unexpected movement of the lift truck as the standard accelerator operates. See Figure 16.
during calibration.
NOTE: Models equipped with the MONOTROL™

feature do not utilize a directional control lever. The
16
1. COVER 4. SPRING
2. SCREWS 5. ATTACHING HARDWARE
3. SWITCHES 6. WIRING HARNESS
Figure 16. MONOTROL™ Directional Control
17
Brakes 2200 SRM 1078
Brakes
BRAKE SWITCH 12. Reconnect the battery and turn the key switch to
the ON position and test for proper function.
The brake switch is located below the floor plates
inside the brake pedal mounting bracket. When
the service brake pedal is in its full up position, it
depresses the switch actuator. Pressing the brake
pedal, even a small distance, releases the actuator.
The controller monitors this circuit and reduces
power to the traction motors when the brake pedal
is depressed.
Adjust or Replace
To adjust the switch:

2. Remove the floormat and floor plates.
3. Depress and hold the brake pedal.
4. Press the actuator of the switch up and down re-

peatedly to check that the switch return spring 1. SCREWS
functions correctly and listen for the "click" of the 2. BRAKE SWITCH
contacts inside the switch. 3. INSULATOR
4. NUTPLATE
5. If in question, tag and disconnect the wiring and 5. SERVICE PEDAL
6. MASTER CYLINDER
remove the switch. Check with an ohmmeter. 7. MOUNTING BRACKET
Replace if necessary.
Figure 17. Brake Switch
6. Position switch to bracket as removed and install
screws and nutplate. Do not tighten. MASTER CYLINDER INDICATOR
or The fluid level in the master cylinder reservoir is
monitored by a float switch, which is part of the reser-
7. To adjust, loosen screws and nutplate holding
voir cap. The switch is normally open when the reser-
switch to bracket.
voir is full. When the oil level in the master cylin-
8. With brake pedal in its full, upright position, der drops below the minimum safe level, the switch
move the brake switch toward the brake pedal closes and an indicator light on the display panel illu-
until the actuator depresses and the contacts in minates. If the indicator light does not come on when
the switch click. Then tighten the screws to hold the oil level is below the minimum safe level, check
the switch in place. the switch by disconnecting the cap wiring harness
and removing the cap assembly. Check that the float
9. Remove the screws and nutplate retaining the moves smoothly and is completely sealed. Check the
switch to the brake pedal bracket. See Figure 17. switch for proper operation using an ohmmeter. Con-
nect the ohmmeter leads to each terminal and check
10. Position the switch against the brake pedal so the resistance while moving the float up and down.
that the actuator is closed when the pedal is in The resistance should increase from 0 to 470 ohms as
its upright position. the float is moved. If the float does not move freely
or if the resistance in not within specification, re-
11. Retighten the screws to securely mount the
place the cap assembly with a new one and install
switch in place. DO NOT OVERTIGHTEN.
the wiring as removed. See Figure 18.
18
2200 SRM 1078 Brakes
1. CAP ASSEMBLY 2. SENSOR WIRES 3. RESERVOIR
Figure 18. Master Cylinder Indicator Switch
PARKING BRAKE DISENGAGE a controlled environment. Additional pre-

cautions and procedures are required when
The parking brakes must be disengaged to perform towing. See Periodic Maintenance 8000 SRM
certain repairs. When certain systems malfunction, 1079, How to Tow Lift Truck.
it may be necessary to tow the lift truck to a different
location to perform service. The parking brakes must To disengage the parking brake in order to perform
be disengaged to tow the truck, also. If towing, move service:
slowly and listen for sounds other than normal. If
the parking brakes do not release or there are other 1. Turn the key switch to the OFF position and dis-
signs of damage (noises), stop towing and repair on connect the battery by pressing the emergency
site or carry the lift truck using a larger lift truck disconnect switch to the STOP position.
if possible. See Periodic Maintenance 8000 SRM
2. Locate the parking brake connectors (BRK_RUN
1079, General for proper towing procedures.
1, BRK_RUN 2, and the BRK_TOWING) beside
the brake diode on the main wiring harness.
Override Mode
These items are found near the front, right
wheel well. See Figure 19.
WARNING
The following procedures refer to overriding
the parking brakes for repair or service in
19
Horn Components and Steering Encoder 2200 SRM 1078
a. Connect jumper wires to each pin of the

BRK_TOWING connector.
b. Connect the red lead of the auxiliary connec-

tor to the positive post of the 24-volt auxil-
iary power source and connect the black lead
to the negative post. Listen for the parking
brakes to release.
4. If a charged battery is installed in the lift truck,

energize the brake override circuit:
a. Disconnect the BRK_RUN 1 and BRK_RUN

2 connectors.
1. BRK_RUN 1
2. BRK_RUN 2 b. Connect the BRK_TOWING and BRK_RUN
3. BRK_TOWING
4. BRAKE DIODE 1 connectors.
5. MAIN WIRING HARNESS
c. Pull the emergency disconnect switch to the
Figure 19. Brake Diode and Release Connectors RUN position and listen for the parking
brakes to release.
3. If a charged battery is not installed in the lift
truck, use an auxiliary 24-volt power supply to 5. Return the truck to operation mode and test for
energize the brake override circuit: proper operation before returning to service.
Horn Components and Steering Encoder

HORN COMPONENTS b. If the voltmeter does read 36/48 ±5 volts, re-
place the horn.
If the horn does not operate properly, there are differ-
ent components that may be at fault. To determine Horn
if the horn itself is faulty, check that 36/48 volts DC
are present at the terminals when the horn button is The horn is the actual audible alarm and is mounted
depressed. to the cowl facing forward. To replace the horn, refer
to the following procedures.
connect the battery. Block the wheel to prevent 1. Remove the cowl cover by removing the four at-
unexpected movement. taching screws.
2. Tag and disconnect the wiring harness connected 2. Tag and disconnect the wires fastened to the horn
to the terminals on the horn. See Figure 20. terminals.
3. Connect a voltmeter lead to each end of the 3. Hold the horn and remove the capscrew, nut,
wiring harness connectors. and washer that fasten the horn to the bracket
welded to the lift truck cowl. Remove the horn.
4. Connect the battery and turn the key switch to
the ON position. 4. Install the new horn and secure using capscrew,
lockwasher, and nut as removed.
5. Press the horn button in the center of the steer-
ing wheel. 5. Install the wires on the horn terminals.
a. If the voltmeter does not read 36/48 ±5 volts, 6. Connect the battery and test for proper opera-
troubleshoot the horn button, horn contacts, tion.
and wiring.
20
2200 SRM 1078 Horn Components and Steering Encoder
7. Reinstall the cowl cover using the four attaching

screws.
Horn Button and Contacts

The horn button and contacts are located on the
steering column. The contacts are mounted on the
front of the steering column, just above the steering
encoder. The horn button, which actuates the con-
tacts, is made into the steering wheel cap. Wires
run from the horn button to the contacts through the
steering column. See Figure 20.
STEERING ENCODER
The steering encoder is fastened to the steering col-
umn with two screws. See Figure 20. Remove the
steering column covers to access the encoder.
1. HORN BUTTON
2. STEERING WHEEL NUT
3. STEERING WHEEL
4. SCREWS
5. HORN CONTACTS
6. SCREW
7. STEERING ENCODER
8. STEERING COLUMN
9. STEERING CONTROL UNIT
Figure 20. Horn Switch and Steering Encoder
21
Steer Angle Potentiometer 2200 SRM 1078
Hood and Seat Switches

HOOD POSITION SWITCHES controller to operate normally. If the operator is
not in the seat, neither the lift pump motor nor the
The hood functions as a restraint to hold the battery traction motors will operate.
in the battery compartment if an accident causes the
lift truck to tip over. A sliding latch mechanism on
the front of the hood locks it closed during operation.
The latch can be accessed by releasing and raising
the hydraulic levers and linkage assembly up and out
of the way. A switch is mounted to the underside of
the hood beside the latch pin. The actuator of the
switch is depressed when the latch pin is in the open
position. The actuator slides down the side of the
latch pin and rests in the groove in the latch pin when
the latch is closed. If the switch actuator does not
enter completely into the groove, the lift truck will
not operate.
A second switch mounted to the right, front under-

side of the hood senses the position of the hood it-
self. The switch actuator is normally depressed by
the truck frame when the hood is in the fully closed
position. When the hood is lifted, the actuator is re-
leased and the controller will not allow the lift truck
to operate. See Figure 21.
SEAT SWITCH
1. HANDLE RECESS
The seat assembly contains an operator presence 2. HOOD (UNDERSIDE)
switch as a safety feature. The seat wiring harness 3. HOOD POSITION SWITCH
connects to switch and exits through the bottom of 4. FRAME
the seat assembly. The operator presence switch is 5. LATCH POSITION SWITCH
located inside the bottom seat cushion. When an
Figure 21. Hood Position Switches
operator sits in the seat, the switch alerts the motor
Steer Angle Potentiometer

GENERAL correct orientation to the steering axle before it can
be properly calibrated. A status code is displayed
The steer angle potentiometer measures the position when the potentiometer is greatly out of adjustment.
of the steer axle and relays this information to the However, a potentiometer that is moderately out of
traction motor controller. The controller can then adjustment may continue to operate. The absence of
modify individual drive motor speeds to improve a status code does NOT necessarily mean that the
the truck’s turning performance. The potentiometer potentiometer is properly adjusted.
facilitates a voltage divider circuit and is rated at
10,000 ohms. OPERATION
The steer angle potentiometer is mounted to the When the steering potentiometer is properly ad-
mounting arm which pivots on the arm stop cap- justed and operating correctly, the input voltage
screw. The potentiometer shaft is attached to the top measured at the traction motor controller is between
of the rotary actuator by a holder and setscrew. The the full left and full right calibration values and
steer angle potentiometer is accessible through the corresponds to the turn angle of the drive tire. The
electrical compartment and must be mounted in the controller retards the traction motor on the side to
22
2200 SRM 1078 Steer Angle Potentiometer
which the steer tire is turned to improve the truck’s Beyond 32 degrees, the maximum lift truck speed is
turning radius. When the drive tire is positioned reduced. The maximum lift truck speed is reduced
straight ahead (0-degree turn angle), the input volt- from full speed at 32 degrees to the value set by Func-
age at the controller should be 2.15 ±0.01 volts. As tion 11 at 90 degrees.
the steer tire is turned left, the input voltage de-
creases and the speed of the left side traction motor Between 66 degrees and 71 degrees, the left wheel is
is reduced. As the steer tire is turned right, the in a free-wheel mode.
input voltage increases and the speed of the right
As the steer angle reaches the 71-degree point, the
side traction motor is reduced. Refer to Figure 22 for
left wheel begins to turn in the opposite direction and
the correlation between the turn angles of the steer
accelerate proportionally.
tire and the input voltages to the controller.
Beyond 86 degrees, the steer angle potentiometer is
outside the normal range of travel.
POSITION STEER TIRE FOR STRAIGHT

TRAVEL
The steer tire must be positioned so the truck trav-
els in a straight line within 152 mm (6 in.) over a
distance of 9 m (30 ft) before adjustments are made
to the steer angle potentiometer. The following
procedure is used to verify that the truck travels
in a straight line for 9 m (30 ft). If the truck does
not travel straight within the tolerance allowed, the
steer tire should be repositioned using the steering
control handle until the truck can be operated in a
straight line, as described, within the specified tol-
erance. The steer tire must be exactly positioned for
straight travel before adjustments can be properly
made to the steer angle potentiometer.
NOTE: This procedure requires a section of floor that

is smooth and level for approximately 30 m (100 ft).
1. LOWEST VOLTAGE (HIGH RESISTANCE) 1. Move the steering control wheel so the steer
2. DEAD AREA (INFINITE RESISTANCE) tire is positioned for straight travel. Operate
3. HIGHEST VOLTAGE (LOW RESISTANCE) the lift truck slowly, while holding the steering
4. MIDPOINT
wheel stationary, for 9 m (30 ft). The steer tire
Figure 22. Potentiometer Input is in the proper position when the lift truck will
travel within 152 mm (6 in.) of a straight line for
Example 9 m (30 ft). Check that the lift truck moves in a
straight line as follows:
The following series of events takes place in a left
turn from the 0- to 90-degree steer wheel position. a. Install a pointer on the outside of the lift
truck, forward of the counterweight. The
In the first 25 degrees of travel (2.15 to 1.81 wiper pointer should be positioned so it does not
volts), there is no change to the wheel speed on the touch the floor. A wire tie can be secured to
inside of the turn (left wheel). the frame with duct tape to serve as a pointer.
Between 25 degrees (1.81 wiper volts) and 66 de- b. Mark the floor under the point of the pointer.
grees (1.10 wiper volts), the left motor reduces speed
proportionally from top speed at 25 degrees to creep c. Operate the lift truck slowly for 5 m (16 ft).
speed at 66 degrees. The operator should not move the steering
control handle while traveling, and the lift
23
Steer Angle Potentiometer 2200 SRM 1078
truck should coast to a stop. Mark the floor 3. Turn the potentiometer arm 180 degrees to the
under the point of the pointer. midpoint. The ohmmeter should read approxi-
mately 5000 ohms. Remove the ohmmeter leads.
d. Operate the lift truck slowly in the same di-
rection for another 5 m (16 ft). The opera- Install to Steer Axle
tor should not move the steering control han-
dle while traveling and allow the lift truck For the following procedures, refer to Figure 23.
to coast to a stop. Mark the floor under the
point of the pointer.
e. With an assistant, pull a string in a straight

line between the first and last marks. The
center mark must be within 76 mm (3 in.) of
the string. If the center mark is not within
76 mm (3 in.), the steer tire is positioned in-
correctly. Reposition the steer tire with the
steering wheel and repeat this procedure un-
til the steer tire is correctly positioned.
f. Remove the pointer.
2. When the steer tire has been correctly positioned,

the steer angle potentiometer can be installed.
INSTALL
Set Potentiometer to Midpoint
For the following procedures, refer to Figure 22. 1. JAM NUT 6. MOUNTING
2. ARM STOP HARDWARE
CAPSCREW 7. HOLDER
NOTE: The steer tire cannot be seen from the seat. 3. SETSCREW 8. STEER AXLE
Have an assistant watch the steering tire and advise 4. MOUNTING ARM HOUSING
you of its position. 5. POTENTIOMETER
1. On a clean workbench, touch the leads of an ohm- Figure 23. Steer Potentiometer Mounting
meter to the middle and one of the outside pins
on the steering potentiometer connector.
CAUTION
2. Position the potentiometer shaft where its high- Be careful not to move the potentiometer shaft
est resistance (infinity) and its lowest resistance when installing to the steering actuator. If the
meet. shaft is accidentally moved, realign the marks
on the potentiometer and shaft (Step b) and
a. Turn the potentiometer shaft until the ohm- continue from Step 3.
meter reaches it highest resistance (infinity).
1. Remove the hardware from the potentiometer,
b. Draw a straight, continuous line down the install the potentiometer to the mounting arm,
shaft and onto the base of the potentiometer, and reinstall hardware. Position the potentiome-
using a marker to mark the position. ter with its wiring harness toward the slot in the
mounting arm and torque the nut to 1.24 N•m
CAUTION (11 lbf in) to secure in position.
Do not move the shaft of the potentiometer 2. Make sure the steer tires are positioned for
after this point. If the shaft is accidentally straight travel. See Position Steer Tire for
moved, realign the marks on the potentiome- Straight Travel.
ter and shaft (Step b) and continue from Step 3.
24
2200 SRM 1078 Steer Angle Potentiometer
4. Install the arm stop capscrew down through the 13. Press button 4 to initiate calibration mode.
slot on the mounting arm and into the steering
actuator housing and tighten the jam nut. 14. Slowly turn the steering wheel to the full left po-
sition.
5. Carefully position the potentiometer (shaft
down) into the holder. 15. Press the Star button to save the values.
6. Tighten the holder setscrew to secure the poten- 16. Press button 3 to back out on level.
tiometer shaft in place.
17. Press button 1 or button 2 to scroll to “Max Steer
7. Connect the potentiometer wiring harness, as re- 0.” Press button 4 to display the current values.
moved. Use a new wire tie to secure it to the arm
18. Press button 4 again to initiate calibration mode.
stop capscrew.
NOTE: The steer tire cannot be seen from the seat.
8. Reconnect the battery and calibrate the steering
Have an assistant watch the steering tire and advise
potentiometer using the display panel. See Cali-
you of its position.
brate.
19. Turn the steering wheel to position the steer tires
Calibrate for straight travel.
The following procedures use the display panel to cal- 20. Press the Star button to save the values.
ibrate the controller values for the steering poten-
tiometer. Refer to Figure 9. 21. Press button 3 four times to completely back out
of service mode.
1. From the seat, turn the key switch to the ON
position. 22. Test the truck for proper operation in a safe, un-
obstructed area.
2. Press the Star button on the display panel two
times to display the password login. TEST
3. Enter the service password. The steer angle potentiometer is tested by measur-
ing resistance values after disconnecting the poten-
4. Press button 1 or button 2 to scroll to “Setup.”
tiometer from the truck wiring harness. Refer to Ta-
5. Press button 4. “Traction Settings” will display. ble 1. Connect an analog volt-ohmmeter to the de-
sired test points and slowly rotate the potentiome-
6. Press button 4. “Throttle Calibration” will dis- ter shaft. The needle on the meter should sweep
play. smoothly from the minimum to maximum value. Re-
place the potentiometer if the needle movement is er-
7. Press button 1 or button 2 to scroll to “Max Steer ratic through the range from minimum to maximum.
Right” and press button 4 to display the current
values. Table 1. Potentiometer Specifications
8. Press button 4 again to initiate calibration mode. Test Points Resistance Value
9. Slowly turn and hold the steering wheel in its full Between pot terminals 10K ±10%
right position. 1 and 3
10. Press the Star button to save the values. Between pot terminals 0-10K ±10%
1 and 2
11. Press button 3 to back out one level.
Between pot terminals 0-10K ±10%
12. Press button 1 or button 2 to scroll to “Max Steer 2 and 3
Left.” Press button 4 to display the current val-
ues.
25
Wiring Harness 2200 SRM 1078
Wiring Harness
The wiring harness is a series of wires bound to- damaged before it is replaced. Make sure malfunc-
gether which carry power and electrical signals tions in the system are not being caused by a con-
throughout the electrical system. The controller nector or connection before replacing wires or compo-
monitors signals from various sensors through the nents. Determine the cause of the damage and rec-
wiring harness and sends instructions and power tify the problem before correcting the wiring to pre-
for different components. Resistor assemblies are vent the same problems from occurring again. If a
present throughout the wiring harness to protect wire or cable is damaged, replace the wire and any
certain systems. connectors using the correct size and type replace-
ment parts. For specific wiring harness functions,
If there is damage to the wiring harness, it may be see Figure 24.
possible to replace only a few wires instead of the
entire wiring harness. Wires and cables do not nor-
mally need replacing. Make sure the wire or cable is
26
2200 SRM 1078 Wiring Harness
1. Steer Encoder (SE) 36. BRK TOWING

2. Horn Switch (HS2) 37. Diode Connector
3. Horn Switch (HS1) 38. Brake Diode
4. Key Switch (Run) 39. Control Valve
5. Key Switch (Bat) 40. Fuse (FU15B)
6. Directional Switches 41. Fuse (FU12B)
7. Dash 42. Fuse (FU14B)
8. PC Connection 43. Fuse (FU13B)
9. Valve Controller 44. Fuse (FU11B)
10. CANbus Resistor 45. Fuse (FU14A)
11. Resistor Connector 46. Fuse (FU13A)
12. (MJ) 47. Fuse (FU11A)
13. Hydraulic Tank Level 48. Fuse (FU12A)
14. Tilt Speed 49. Fuse (FU15A)
15. RH Traction Motor 50. EHB Ground
16. LH Traction Motor 51. Main Contactor (C1)
17. Resistor Connector 52. Main Contactor (C2)
18. CANBUS Resistor 53. Controller (TBC)
19. Steer Pump Motor 54. Controller (TBA)
20. Steer Positive 55. TC Negative
21. Horn 56. Controller (TBD)
22. Brake Coil (C3) 57. Resistor
23. Lift Pump 58. Connector
24. Brake Pedal 59. Seat
25. Brake Coil (C2) 60. Hydraulic Contactor (C1)
26. Throttle Sensor 61. Hydraulic Contactor (C2)
27. Directional Control (FC3) 62. Hood Switch (SW1A)
28. Directional Control (FC2) 63. Hood Switch (SW1B)
29. Directional Control (FC1) 64. Hood Switch (SW2A)
30. Start Traction (SW1) 65. Hood Switch (SW2B)
31. Start Traction (SW2) 66. Auxiliary Connector
32. Brake Fluid (MC1) 67. Steering Potentiometer
33. Brake Fluid (MC2) 68. Emergency Shutoff (ES2)
34. BRK RUN (1) 69. Emergency Shutoff (ES1)
35. BRK RUN (2) 70. Battery Positive
27
Wiring Harness 2200 SRM 1078
28
2200 SRM 1078 Wiring Harness
Figure 24. Wiring Harness
29
NOTES
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30

AC MOTOR
CONTROLLERS/
DISPLAY PANEL
DESCRIPTION, CHECKS,
ADJUSTMENTS, AND
TROUBLESHOOTING
J1.6-2.0XMT (J30-40ZT) [J160]
PART NO. 1554633 2200 SRM 1087

SAFETY PRECAUTIONS

trucks.
nance section.
manual:
WARNING
CAUTION
AC Motor Controllers/ Display Panel Table of Contents
TABLE OF CONTENTS
Description ......................................................................................................................................................... 1
General ........................................................................................................................................................... 1
Description ..................................................................................................................................................... 1
AC Motors .................................................................................................................................................. 1
ZAPI™ AC Motor Controller .................................................................................................................... 1
Principles of Operation ............................................................................................................................. 2
Controller Thermal Management............................................................................................................. 3
Controller Area Network (CAN Bus) ....................................................................................................... 3
AC Motor Controller Repair .............................................................................................................................. 4
General ........................................................................................................................................................... 4
Special Precautions ................................................................................................................................... 4
Thermal Sensors ............................................................................................................................................ 5
Motor Controller, Replace ............................................................................................................................. 5
Controller Checks and Adjustments ................................................................................................................. 5
Function Parameters ......................................................................................................................................... 6
General ........................................................................................................................................................... 6
Function Parameter Description....................................................................................................................... 7
Parameters..................................................................................................................................................... 7
Top Speed Forward.................................................................................................................................... 7
Top Speed Reverse..................................................................................................................................... 7
Acceleration ............................................................................................................................................... 7
Regen Braking ........................................................................................................................................... 8
Auto Deceleration...................................................................................................................................... 8
Extended Shift........................................................................................................................................... 8
Pump Acceleration .................................................................................................................................... 8
Tilt/Auxiliary Pump Acceleration............................................................................................................. 8
Low Lift Speed........................................................................................................................................... 8
Maximum Lift Speed................................................................................................................................. 8
Tilt Speed ................................................................................................................................................... 8
3rd Function Speed ................................................................................................................................... 9
4th Function Installed .............................................................................................................................. 9
4th Function Speed ................................................................................................................................... 9
3rd Function Interlock .............................................................................................................................. 9
4th Function Interlock .............................................................................................................................. 9
Battery Voltage.......................................................................................................................................... 9
Lift Interrupt ............................................................................................................................................. 9
BDI Adjustment ........................................................................................................................................ 9
BDI Decrement Time ................................................................................................................................ 9
Service Reminder ...................................................................................................................................... 10
Custom ....................................................................................................................................................... 10
Restore Defaults ........................................................................................................................................ 10
Calibration Parameters ..................................................................................................................................... 10
Throttle Calibration ...................................................................................................................................... 10
Steering Calibration ...................................................................................................................................... 10
Display Panel ..................................................................................................................................................... 10
General ........................................................................................................................................................... 10
Premium Display Panel ............................................................................................................................ 10
Standard Display Panel ............................................................................................................................ 10
Display Functions and Features ....................................................................................................................... 11
Key-ON Initialization .................................................................................................................................... 11

Table of Contents AC Motor Controllers/ Display Panel

Standard Display ........................................................................................................................................... 11
Premium Display ........................................................................................................................................... 13
Lift Truck Inspection Function ..................................................................................................................... 13
Access to Service Functions .......................................................................................................................... 14
Service Functions .......................................................................................................................................... 14
Performance Modes ....................................................................................................................................... 15
Battery Discharge Indication (BDI) ............................................................................................................. 16
Hourmeter...................................................................................................................................................... 16
Status Code List ............................................................................................................................................ 16
Dash Display Service Menu Navigation ........................................................................................................... 17
General ........................................................................................................................................................... 17
Moving Through Menu Selections ................................................................................................................ 17
Editing and Adding Information .................................................................................................................. 17
General ........................................................................................................................................................... 18
Status Codes .................................................................................................................................................. 18
Controller Connector Pin Outs ..................................................................................................................... 77
Valve Driver Module (Electro-Hydraulic Valve Option) .............................................................................. 79
Hydraulic Lever Console (Electro-Hydraulic Option Only) ........................................................................ 80
Dash Display.................................................................................................................................................. 80
System Logic Diagrams................................................................................................................................. 81
J1.6-2.0XMT (J30-40ZT) [J160]
ii
Description
GENERAL provides feedback to the motor controller, allowing
software to continually monitor motor direction and
This section describes the ZAPI™ AC motor con- revolutions per minute (RPMs). Using this software
troller. See Figure 1. Procedures are outlined for feedback, the AC motor control system can provide
controller safety, adjustments, troubleshooting, and much better vehicle speed control than is available
repair. This section does not contain information with DC SEM systems.
about other electrical components. See the section
Electrical System 2200 SRM 1078 and the sec- The AC motors also have thermal sensors, continu-
tion Electro-Hydraulic Control Valve 2000 SRM ously monitored by the motor controllers, embedded
1086. in the motor windings.


Figure 1. AC Controller
ZAPI™ AC Motor Controller
Throughout this section, forward will refer to travel
in the direction of the forks and left and right are The ZAPI™ controller comes in two versions. See
determined by an operator sitting in the seat facing Figure 3. The first version contains two inverters for
forward. See Figure 2. controlling the dual traction motors and a contactor
for the lift function. The second version contains two
DESCRIPTION inverters for controlling both traction motors and a
transistor controller to control a series DC pump mo-
AC Motors tor.
The AC motors are three-phase AC induction mo- The ZAPI™ controller is a solid state AC motor con-
tors. They do not include motor brushes or commu- troller utilizing MOSFET technology with micropro-
tators. An AC induction motor operates on three- cessor control. The basic dual motor control is capa-
phase AC power provided directly by the motor con- ble of controlling two asynchronous AC induction mo-
troller. The motor’s speed is controlled by the con- tors simultaneously. The controller has direct control
troller and can be changed by the frequency of the of the traction system, main contactor, and the elec-
AC power presented to the motor. A speed sensor tromagnetic parking brakes.
has been built into the rear motor bearing, which
1
operation of the controller. One microprocessor is

designated the master and controls the right traction
motor and the majority of the logic functions for the
controller. The other microprocessor is designated
the slave and controls the left traction motor and
performs fewer functions than the master. The con-
troller has many programmable features, including
maximum speed, acceleration rate, neutral braking,
and brake current limit. The controller includes a
full range of features, as well as diagnostic and setup
capability.
The controller contains two separate DC to AC in-

verters and the logic cards necessary to process in-
put signals from various truck components. The con-
troller uses these inputs to control the speed and di-
rection of the dual traction motors. These compo-
nents are all contained within a single housing lo-
cated on the inside of the rear compartment cover.
See Figure 4.
Figure 3. AC Controllers
The controller software provides self diagnostics

which are accessed by means of a personal computer
(PC) with specialized ETACC software (see the sec-
tion Troubleshooting and Adjustments Using
the AC Controls Program 2200 SRM 1058) or
the on-board Dash Display. The controller software
features a Test Menu for monitoring controller in-
puts and outputs, a Diagnostic Menu for viewing
fault code information, and a Programming Menu
for customizing the truck performance.
The self diagnostics monitor the traction motor,

brake coil, main contactor coil, controller tempera-
ture, and internal logic functions. Troubleshoot fault
codes generated by the controller self diagnostics
by using the on-board dash display or a properly
configured IBM™ compatible PC.
Principles of Operation
1. LH TRACTION MOTOR
The traction motor controllers convert DC power 2. RH TRACTION MOTOR
from the truck’s battery to three-phase AC power 3. DASH DISPLAY
at the frequencies and current necessary to inde- 4. HYDRAULIC VALVE
5. CONTACTOR AND FUSE PANEL
pendently power each traction motor. Each AC 6. TRACTION CONTROLLER
induction motor provides feedback to the controller 7. HYDRAULIC PUMP AND MOTOR
for speed, rotation direction, and temperature. 8. STEERING PUMP AND MOTOR
The ZAPI™ AC motor controller uses two sophis- Figure 4. Component Location
ticated microprocessors to control the logic and
2
The controller may also be equipped with an optional

transistor pump motor controller. This transistor WARNING
control is installed in a single housing along with the DO NOT short across the motor controller ter-
two inverters for powering the traction motors. The minals with a screwdriver or jumper wire.
pump controller receives inputs from the hydraulic
valve or the optional valve driver module. The pump NOTE: Some lift trucks are equipped with a premium
motor will run at specific preset motor speeds when controller, which controls the hydraulic motor as well
the manual control valve is installed. Motor speed is as the traction motors.
based on the hydraulic function selected. 1. Discharge the capacitor in the controller by con-
Controller Thermal Management controller’s BT+ and B terminals for 10 seconds
The motor controller is equipped with internal ther- using insulated jumper wires. See Figure 5.
mal sensors to protect the controller from a high tem- 2. On the premium controller, also connect the 200-
perature condition. At a temperature of 80 C (176 F), ohm, 2-watt resistor across the controller’s P+
the controller will begin to reduce current to the trac- and B terminals for 10 seconds using insulated
tion circuit and slow the speed of the lift truck. If jumper wires. See Figure 6.
the controller temperature continues to rise, the trac-
tion current will be further reduced. If the temper- 3. Remove the 200-ohm, 2-watt resistor before re-
ature reaches 100 C (212 F), current to the traction connecting the battery.
circuit will be reduced to zero and the lift truck can-
not travel. As the controller cools, traction will be NOTE: There are no user-serviceable parts in the
restored. When the controller has cooled to 80 C ZAPI™ controller. No attempt should be made to
(176 F), full traction speed will be available. open, repair, or otherwise modify the controller. Do-
ing so may damage the controller and will void the
Controller Area Network (CAN Bus) warranty.
The motor controller and the dash display are con-

nected together with a CAN bus communication
system. When equipped with the optional elec-
tro-hydraulic valve, the valve, valve driver module,
and the electro-hydraulic lever console also commu-
nicate with the ZAPI™ controller over the CAN bus
network. A PC with the appropriate service software
can easily communicate with all system nodes by
simply connecting to the CAN bus. A special connec-
tor, located under the dash and next to the display,
is configured specifically for this purpose.
WARNING
and personal injury, discharge the capacitor 1. POSITIVE CONNECTION (BT+)
before inspecting or repairing any component 2. NEGATIVE CONNECTION (B )
in the electrical compartment. Wear safety 4. 200-OHM, 2-WATT RESISTOR
been disconnected. Figure 5. Discharging the Capacitors -
Economy
3
AC Motor Controller Repair 2200 SRM 1087
Legend for Figure 6

Figure 6. Discharging the Capacitors -

Standard and Premium
AC Motor Controller Repair

GENERAL Make sure you disconnect the battery and
separate the connector before you remove any
There are NO internal parts of the controller that can power cables from the power terminals of the
be repaired. The controller must be replaced if an motor controller. The capacitor stores elec-
internal malfunction occurs. trical energy and can cause injury if a person
discharges a capacitor through parts of the
The motor controller, like other electronic devices,
body. AFTER the battery is disconnected and
has temperature limits. These devices can be dam-
the key is in the OFF position, make sure you
aged if they get too hot. Normal maintenance will
discharge the capacitors.
help prevent high-temperature conditions. Always
make sure components are installed using silicon
grease and that all heat sink surfaces are clean. Do CAUTION
not block cooling airflow. To help prevent controller damage:
ALWAYS disconnect the battery when servic-
Special Precautions ing the controller.
ALWAYS discharge the capacitors before
WARNING performing any service.
To avoid injury and prevent electrical shock, NEVER connect power to the motor con-
perform the following steps before trou- troller when any power cable is discon-
bleshooting, adjustments, or repairs: nected.
Turn the key to the OFF position and discon- NEVER make a short circuit at any motor
nect the battery connector. controller terminal to battery (+), battery
Discharge the capacitors in the controller. ( ), or the frame.
Check with the dealer for your lift truck before oper-
WARNING ating in an area with normal temperatures over 40 C
Some checks in this section must be done with (104 F) The lift truck motor controller may not oper-
the battery connected and power applied to the ate at full power under these conditions.
controller. When making these checks, make
sure the drive wheels are raised from the floor.
4
2200 SRM 1087 Controller Checks and Adjustments
MOTOR CONTROLLER, REPLACE

CAUTION
Never add any electrical component to the Make sure the battery is disconnected and the capac-
lift truck without approval from your Hys- itors are discharged. Replace the motor controller as
ter dealer. Added electrical components can described in the following procedure.
prevent operation and/or damage the motor
1. Tag and disconnect all wire harness connections
controller.
and power wires from the controller.
Never use steam to clean electronic compo-
2. Remove the mounting screws holding the con-
nents. In dusty areas, blow low pressure air over
troller to the rear compartment cover. Carefully
the controller to remove dust. In oily or greasy areas,
remove the controller from the truck.
a mild solution of detergent or denatured alcohol
can be used to wash off the controller. Then use low
pressure air to completely dry the controller. CAUTION
Do not remove the screws that secure the cover
CAUTION of the controller.
Do NOT operate the traction system at high 3. Ensure there is no dirt between the base of the
speeds or rapidly change the direction of oper- controller and the mounting surface on the rear
ation with the wheels raised. Motor controller compartment cover.
damage can occur.
4. Put an even coat of thermal grease on the base
Do not subject the controller to any high voltage plate of the controller. Ensure there are no air
(hipot or megger) testing. spaces between the plate and the mounting sur-
face of the rear compartment cover. The base
Use a lead acid battery with the voltage and ampere
plate of the controller must make full contact
hour rating specified for the lift truck. Follow nor-
with the mounting surface.
mal battery maintenance procedures, recharging be-
fore 80 percent discharged, with periodic equalizing 5. Install the screws that fasten the controller to the
charges. rear compartment cover.
THERMAL SENSORS 6. Reconnect all power wires and wire harness con-
nections to the controller.
The thermal sensors for the motors are embedded in
the motor end head and are continuously monitored 7. Calibrate steering and throttle inputs. See Cali-
by the motor controller. They are part of the motor bration Parameters in this section.
and cannot be repaired.
Controller Checks and Adjustments

All checks and adjustments to the controller can be • Check the system status codes in history.
done with a PC or through the dash display on the • Check the state of charge of the battery.
instrument panel. A PC can be connected to the CAN • Check the hourmeter readings on the traction cir-
bus via a connector on the main wiring harness near cuit and hydraulic pump controllers.
the bottom (backside) of the display panel. • Monitor or adjust the register values for each func-
tion as shown in Function Parameters in this sec-
The following checks and adjustments may be made tion.
using a PC or the dash display:
5
Function Parameters 2200 SRM 1087
Function Parameters
GENERAL Table 1. Traction Parameters
Memory elements within the controller are called Control Settings

registers. These registers can have electronic data
stored in them to control an operation. The data Factory Defaults
Traction
stored in a register is called a parameter. A pa- 36V 48V
rameter is a measurement number that defines a
lift truck function. A specific function parameter Battery Voltage 36 48
works with other function parameters to control the Extended Shift ON ON
operation of the lift truck.
Acceleration 0 0
WARNING Top Speed Max FWD 128 Hz 140 Hz

The parameter for each function has a value Top Speed Max REV 128 Hz 140 Hz
range so the motor controller can be used on
Regen Braking 9 9
different models of lift trucks. This variation
is needed for lift trucks of different sizes and Auto Deceleration 6 6
operating voltages. Adjustment of a function
BDI Adjustment 2 2
to the wrong number value for your lift truck
model can cause the truck to operate differ- Lift Interrupt 1 1
ently than normal. This different operation of
Service Reminder 0 0
the truck can cause an injury.
Custom 0 0
NOTE: Table 1, Table 2, and Table 3 show the de-
fault parameter setting for each control function that
is adjustable by the user. The factory-set default Table 2. Transistor Lift With Manual
parameters are the recommended settings for new Valve Parameters
units. These settings will give satisfactory perfor-
mance for most applications. Control Settings
Some functions can be adjusted within the permitted Transistor Lift With Factory Defaults
range to change the lift truck operation for a specific Manual Valve 36V 48V
application. Adjustment of a register to a number
that is different than the factory settings is allowed, Pump Acceleration 1 1
but follow the instructions carefully. Adjustments 100 100
Max Lift Speed
other than the factory settings will cause the lift
truck to operate differently and can cause increased Low Lift Speed 40 30
wear of parts. Tilt Speed 58 40
3rd Function Speed 33 25
4th Function Speed 85 85
6
2200 SRM 1087 Function Parameter Description
Table 3. Transistor Lift With Electro-Hydraulic Table 3. Transistor Lift With Electro-Hydraulic
Valve Parameters Valve Parameters (Continued)
Control Settings
Control Settings
Transistor Lift With Factory Defaults
Transistor Lift With Factory Defaults
Electro-Hydraulic
36V 48V Electro-Hydraulic
Valve 36V 48V
Valve
Pump Acceleration 1 1
4th Function Installed 0 0
Max Lift Speed 100 100
3rd Function Interlock 0 0
Max Lowering Speed 75 75
4th Function Interlock 0 0
Tilt Speed 33 25
Tilt/Auxiliary Pump 4 4
3rd Function Max Speed 33 25 Acceleration
4th Function Max Speed 85 85
Function Parameter Description

PARAMETERS the load on the forks. Acceleration rates are
also unaffected by lowering the top speed.
WARNING
If any of the parameter values are changed, the
Top Speed Reverse
operators must be told that the lift truck will (Scale 0-140 Hz)
operate differently.
This parameter setting determines the top speed of
WARNING the truck in the reverse direction.
NEVER adjust any of the following parameters To increase the top speed above the factory setting,
without using the procedures and settings the extended shift parameter will need to be dis-
given in this section. abled.
The following section contains descriptions for the To reduce the top speed below the factory setting,
different parameters. Access these parameters the extended shift parameter may be enabled or
through the SETUP menu in the dash display or disabled.
with the PC software.
For speed limits slower than the normal truck
Top Speed Forward speed, the top speed is the same regardless of
the load on the forks. Acceleration rates are
(Scale 0-140 Hz) also unaffected by lowering the top speed.
This parameter setting determines the top speed of
Acceleration
the truck in the forward direction.
(Scale 0-9)
To increase the top speed above the factory setting,
the extended shift parameter will need to be dis- This parameter setting determines the truck accel-
abled. eration rate. The truck will accelerate at this rate
regardless of the load on the forks, provided that the
To reduce the top speed below the factory setting,
motor and control can deliver the required power.
the extended shift parameter may be enabled or
disabled. To increase the acceleration rate above the factory
setting, the extended shift parameter will need to
For speed limits slower than the normal truck
be disabled.
speed, the top speed is the same regardless of
7
Function Parameter Description 2200 SRM 1087
To reduce the acceleration rate below the factory Grade climbing speed will also improve be-
setting, the extended shift parameter may be en- cause the motor controller will deliver max-
abled or disabled. imum current. Any increase in performance
will decrease the battery shift life.
Any increase in performance will decrease the bat-
tery shift life. Pump Acceleration
Regen Braking (Scale 0-9)
(Scale 0-9) This parameter setting determines the hydraulic

pump motor acceleration rate. Increasing the setting
This parameter setting determines the maximum de- will increase the speed of the motor.
celeration rate when the accelerator pedal is fully de-
pressed during regen braking. Tilt/Auxiliary Pump Acceleration
NOTE: The deceleration rate is less when the pedal (Scale 0-9)
is not fully depressed.
This parameter setting determines the hydraulic
Auto Deceleration pump motor acceleration rate when using the tilt or
auxiliary functions with the electro-hydraulic valve
(Scale 0-9) option.
This parameter setting determines the maximum
Low Lift Speed
deceleration rate when the accelerator pedal is
released. The strength of auto deceleration is a (Scale 36V = 25-65%)
percentage of the regen braking strength. (Scale 48V = 20-50%)
A setting of zero will turn off auto deceleration com- This parameter setting determines the hydraulic
pletely and a setting of nine will give auto decelera- pump motor low speed. This is used with transistor
tion the same strength as regen braking. lift and the manual control valve. Increasing the
setting will increase the speed of the hydraulic pump
Extended Shift motor.
(0 or 1)
Maximum Lift Speed
(0 = Disable; 1 = Enable)
(Scale 36V = 40-100%)
This parameter setting enables or disables a pre-
(Scale 48V = 30-100%)
set motor performance program in the traction motor
controller. This parameter setting determines the hydraulic
pump motor high speed. High speed is used for
When enabled, this function provides a balance be-
maximum lift speed.
tween truck performance and battery shift life that
will meet the requirements of most applications. Tilt Speed
Truck acceleration and top speed will vary with the
amount of load on the forks. (Scale 36V = 20-66%)
(Scale 48V = 15-50%)
When disabled, truck acceleration and top speed are
determined by values set in the acceleration and top This parameter setting is used to set the hydraulic
speed parameters. motor speed when the tilt function is selected. In-
creasing the setting will increase the speed of the hy-
If the motor and controller can deliver the power, draulic pump motor.
then the truck performance will not vary with the
amount of load on the forks or the battery state of
charge.
8
2200 SRM 1087 Function Parameter Description
3rd Function Speed Lift Interrupt

(Scale 36V = 20-100%) (0 or 1)
(Scale 48V = 15-75%) (0 = Disable; 1 = Enable)
This parameter setting is used to set the hydraulic This parameter setting enables or disables the lift
pump motor speed when the 3rd function hydraulic interrupt feature. The lift interrupt feature stops lift
lever is actuated. Increasing the setting increases operation when the battery discharge indicator (BDI)
the speed of the hydraulic pump motor. reads empty to protect the battery from excessive
discharge and possible damage.
4th Function Installed
NOTE: Trucks are shipped from the factory with this
(0 or 1) feature enabled.
(0 = Disable; 1 = Enable)
BDI Adjustment
This parameter setting is used to tell the controller
when a four function hydraulic valve is installed on (Scale 0-9)
the lift truck. Enabling this parameter indicates the
forth function is installed. This parameter setting allows for adjustment to im-
prove the accuracy of the Battery Discharge Indi-
4th Function Speed cator in the dash display. Increasing the setting will
increase the battery voltage or specific gravity when
(Scale 36V = 0-100%) the gage shows empty.
(Scale 48V = 0-100%)
A setting of 2 is the recommended starting
This parameter setting is used to set the hydraulic point for flooded cell batteries. A setting of 7
pump motor speed when the 4th function hydraulic is the recommended starting point for main-
lever is actuated. Increasing the setting increases tenance-free batteries. Further adjustments
the speed of the hydraulic pump motor. may be used to fine-tune the BDI accuracy.
3rd Function Interlock BDI Decrement Time

(0 or 1) This adjustment is used to compensate for duty cy-
(0 = Disable; 1 = Enable) cles that involve nonstop operation where frequent
pauses of more than 5 seconds do not occur (no drive,
This parameter setting is used with the optional elec- no hydraulic use). When the truck is finally stopped,
tro-hydraulic valve. Enabling this function will acti- turned OFF, and then restarted, some deviation
vate the interlock on the 3rd function hydraulic lever. in the BDI reading may occur. One of three things
may happen to the BDI reading when the truck is
4th Function Interlock restarted:
(0 or 1) 1. The BDI gage still reads within plus or minus one
(0 = Disable; 1 = Enable) bar as it did when the truck was turned OFF. No
adjustment is needed.
This parameter setting is used with the optional elec- 2. If the BDI gage changed downward more than
tro-hydraulic valve. Enabling this function will acti- one bar, this parameter should be set to a lower
vate the interlock on the 4th function hydraulic lever. number.
3. If the BDI gage changed upward more than one
Battery Voltage bar, this parameter should be set to a higher
number.
(36V or 48V)
This adjustment has little or no effect on the BDI
This parameter setting is used to inform the mas- accuracy when the truck is used in intermittent duty
ter controller what voltage battery is installed in the cycles that have frequent pauses in truck activity for
truck. The battery choices are 36V or 48V. greater than 5 seconds each time.
9
Display Panel 2200 SRM 1087
Service Reminder Custom

(Set Next Hourmeter) (Scale 0-100)
This can be used by the service technician to show a This parameter setting is not used except for special
Status Code 99 when the truck is due for service. functions required for special applications. Normally
it is set to zero.
To use this feature, set this function to the hourme-
ter reading at which the service is to occur. When Restore Defaults
that hourmeter is reached, the dash display will dis-
play Status Code 99 for 10 seconds each time the key This function is used to restore all parameter settings
is turned ON. After 20 hours of operation, the truck to the factory default settings shown in Table 1, Ta-
will slow to half speed and the code will display con- ble 2, and Table 3.
tinuously until the service is performed. After ser-
vicing, adjust the service reminder parameter to the
next desired service time.
Calibration Parameters
THROTTLE CALIBRATION STEERING CALIBRATION
Activating this parameter allows the controller to Activating this parameter allows the controller to
“learn” the voltage setting of the throttle assembly. “learn” the voltage setting of the steering feedback
The controller uses this information to control the system. The controller uses this information to con-
lift truck speed. See the section Electrical System trol the traction motors during turning operations.
2200 SRM 1078. See the section Electrical System 2200 SRM 1078.
Display Panel
GENERAL • Allows access to the User Check List function.
There are two dash display options, Standard and Standard Display Panel
Premium. Both displays look identical. See Figure 7.
• Allows preassigned service passwords to control ac-
Premium Display Panel cess to the service functions available through the
display.
• Allows preassigned user passwords to control • Provides the same comprehensive set of Service
driver access to the vehicle. Functions using the Mode buttons and LCD as the
• Provides four driving Modes that are accessed Premium Display.
through the key pad.
• Allows preassigned service passwords to control ac- Standard and Premium display panels are inter-
cess to the service functions available through the changeable on the vehicle. Therefore, the display
display. system can be easily upgraded or downgraded by
• Provides a comprehensive set of Service Functions changing the display panel.
which are accessed through the Mode buttons and
liquid crystal display (LCD).
10
2200 SRM 1087 Display Functions and Features
Figure 7. Standard and Premium Display Panel
Display Functions and Features

KEY-ON INITIALIZATION STANDARD DISPLAY
Upon turning the key to the ON position, the display Following the sequence given above, and as the seat
sequentially lights the indicators, from left to right, belt light becomes illuminated, the LCD displays the
located along the top of the display. See Figure 8. BDI as a bar. See Figure 9. As the battery is dis-
charged, the bar becomes shorter.
NOTE: The seat belt light will stay on whether the
seat belt is fastened or not fastened.
The indicator lights turn off sequentially, except for

the seat belt light, which will remain lighted for ap-
proximately 10 seconds.
11
Display Functions and Features 2200 SRM 1087
1. HOURMETER INDICATOR 8. LCD SCREEN

2. WRENCH INDICATOR 9. STAR PUSH BUTTON
3. BATTERY INDICATOR 10. PUSH BUTTON #1
4. BATTERY DISCHARGE INDICATOR (BDI) 11. PUSH BUTTON #2
5. BRAKE FLUID LEVEL 12. PUSH BUTTON #3
6. PARKING BRAKE 13. PUSH BUTTON #4
7. FASTEN SEAT BELT 14. PUSH BUTTON #5
Figure 8. Dash Display

Legend for Figure 9
1. 4 SEGMENTS ADJACENT TO RED
2. 4 SEGMENTS ADJACENT TO ORANGE
3. 12 SEGMENTS ADJACENT TO GREEN
4. BDI SHOWS APPROXIMATELY 65-70% CHARGE
Figure 9. Battery Discharge Indicator
12
When the key is turned to the OFF position, the

Hourglass indicator becomes illuminated, and the
following hourmeter information is flashed on the
LCD screen: Traction Hours for 3-4 seconds, followed
by Pump Hours for 3-4 seconds, after which the dis-
play turns off and appears black. See Figure 10.
Figure 12. Display Screen (Premium Display)
LIFT TRUCK INSPECTION FUNCTION

If this function is turned on, the operator is prompted
to answer a checklist of questions. The operator in-
dicates a 1 for pass or a 4 for fail. If the operator
indicates the vehicle passes the inspection, the dis-
play will show the previous information and the op-
erator can drive the vehicle. If the operator indicates
that the vehicle fails the inspection, Service Required
Figure 10. Traction/Pump Hours
will appear on the display screen, and the vehicle will
only operate in Mode 1 until the required action is
PREMIUM DISPLAY
taken. See Figure 13.
Following the sequence given above, and as the seat
belt light becomes illuminated, the LCD displays the
prompt for the operator to enter a password if this
function has been enabled. See Figure 11. If the
password function is disabled, the display will bypass
the password prompt. To enable the password func-
tion, see the password menu.
Figure 13. Inspection Failure Screen
The inspection feature can be enabled with or with-

out the password function enabled, depending upon
the user’s preference. The inspection checklist fea-
ture, as with the password feature, may be set up us-
ing either the dash display or using a PC. The check-
Figure 11. Password Prompt Screen list must be enabled or disabled by a service techni-
cian.
Until a password is entered that agrees with a pass-
word stored in the dash display, the lift and traction The following is the list of checks:
systems are inoperative. Passwords may be entered • Check for leaks.
directly into the dash display or by using the PC soft- • Check service brake.
ware program. • Check park brake.
• Check horn, lights, and reverse alarm.
A few seconds after the correct password has been en- • Check gauges and warning lights.
tered, the BDI and Performance Mode are displayed • Check tire condition and pressure.
and the vehicle can be operated. See Figure 12. • Check hydraulic oil level.
13
ACCESS TO SERVICE FUNCTIONS • View Hourmeter

Secure Hourmeter
All service functions are accessible from either Stan- Set Pump Hours
dard or Premium displays. The following functions Set Traction Hours
are the same with either display version, except as • Software Version
noted in the following sections. Master
Slave
Once the vehicle is turned ON with the key switch
Display
and the initialization process has been completed, a
Valve Driver (Electro-Hydraulic only)
service technician can gain access to the service func-
• Password
tions by pressing the star button (*) twice within 3
Add Password
seconds.
Delete Password
The display will prompt the service technician for a Edit Password
five-digit password. See Figure 14. The default set- Operator Password
ting for the password is 55555. When a correct pass- Truck Inspection
word is entered, the Service Features menu is dis-
NOTE: All indications in the diagnostic menu are
played as follows:
shown as ON, OFF, (or a value i.e. volts, amps). ON
• Hourmeters
is indicated by a one. OFF is indicated by a zero.
• Software Versions
• Password • Diagnostic
• Diagnostics Error Log
• Setup Run Diagnostics
Left Trac Mtr Speed
Left Trac Mtr Crrnt
Left Trac Mtr Temp
Right Trac Mtr Speed
Right Trac Mtr Crrnt
Right Trac Mtr Temp
Steer Position
Lift Transistor Control
Pump Motor Voltage
Figure 14. Password Request Pump Motor Current
No Run Diagnostics
The technician can scroll through the menu using the
Hood Switch
up [1] or down [2] arrows and select the desired func-
Seat Belt Switch
tion by pressing the [4] button. Each menu selection
Seat Switch
has a list of submenu functions. The submenus are
Forward Switch
viewed and items selected by scrolling through the
Reverse Switch
menu in the same manner as described above.
Accelerator Start
To exit a selected function and return to the previous Brake Switch
function, press the [3] button. Pressing the [3] but- Brake Fluid Level
ton multiple times will return the technician to the Hydraulic Oil Level
operator’s driving mode. Pump Motor Brushes
Pump Motor Temp
SERVICE FUNCTIONS Throttle Pot Volt
Steering Enable
The following submenu functions are accessible from Manual with Transistor Control
the main menu of service functions, described above. Lo Lift Switch
This includes the following vehicle setup values and Lift Switch
control function settings. The control function set- Tilt Switch
tings are discussed further in Function Parameter 3rd Function Switch
Description. 4th Function Switch
14
Electro-Hydraulic Service Reminder

Arm Rest Switch Custom
Lift Speed Language
Lower Speed
Tilt Forward Speed PERFORMANCE MODES
Tilt Back Speed
3rd Func In Speed NOTE: Performance modes are not available on the
3rd Func Out Speed Standard Dash display, and the factory configuration
4th Func In Speed is equivalent to Mode 4.
4th Func Out Speed
When equipped with the Premium Dash display,
Manual
the following four operator-selectable performance
Hydraulic Switch
modes are available. These modes are preconfigured
• Setup
from the factory as described below. Mode 4 provides
Traction Settings
the highest performance and Modes 1-3 are percent-
Throttle Calibration
ages of Mode 4. A service technician, using the dash
Max Steer Right
display or connecting with the PC software, can re-
Max Steer Left
vise the control settings and configure the top speed
Max Steer 0
and acceleration of the vehicle. The relationship
Top Speed Forward
between Modes 1-4 remains constant and cannot be
Top Speed Reverse
altered.
Acceleration
Regen Braking With the premium display, the operator can change
Auto Deceleration modes by pressing the numbered keys on the dash
Extended Shift display. Any number can be selected at any time to
Hydraulic Settings change the performance mode. If the mode change
Manual with Transistor Controller is requested while the traction system is in opera-
Lift Pump Accel tion, the requested change will not take effect until
Tilt/Aux Pump Accel the accelerator pedal has been released to the neutral
Lo Lift Speed position. During this operation, the display will indi-
Max Lift Speed cate Mode X Requested until the accelerator is re-
Tilt Speed leased. If the password is enabled, the operator will
3rd Function Speed be limited by the performance level set in the pass-
4th Function Speed word function.
Electro-Hydraulic
4th Function Installed Mode 4 is the highest level of performance available
Lift Pump Accel to the operator, regardless of the performance setup
Tilt/Aux Pump Accel in the control. For instance, if the control is con-
Max Lift Speed figured to limit top speed less than maximum, then
Lowering Max Speed Mode 4 top speed is equal to the top speed set in the
Tilt Max Speed control. Three lower performance modes are avail-
3rd Function Max Speed able to the operator by using the buttons on the dis-
4th Function Max Speed play. These lower performance settings are percent-
3rd Function Interlock ages of the highest performance available in Mode 4
4th Function Interlock as described below:
Manual • Mode 4 - This is the highest performance mode.
No Parameters Will Display Other modes are a lower percentage of Mode 4.
Truck Settings • Mode 3 - Top speed is the same as Mode 4. Accel-
Serial Number eration is 80 percent of Mode 4.
Battery Voltage • Mode 2 - Top speed is 80 percent of Mode 4. Accel-
Lift Interrupt eration is 70 percent of Mode 4.
Restore Defaults • Mode 1 - Top speed is 60 percent of Mode 4. Accel-
BDI Adjustment eration is 60 percent of Mode 4.
BDI Decrement Time
15
BATTERY DISCHARGE INDICATION (BDI) battery is reconnected to the lift truck. In order to
reset the BDI function and allow lift truck operation,
The AC control system includes a Battery Discharge the recharged battery must have a state of charge
Indicator (BDI) that provides indication of the bat- that is 20 percent above the open cell voltage BDI
tery state of charge. See Figure 15. The BDI feature setting.
is displayed to the operator on the dash display with
a 20-segment bar that looks and functions the same Two BDI adjustment features are provided via the
as the current BDI. Lift truck operators will not need control setup function, which is accessible via the
to learn a new BDI system. dash display (service password required) or with the
PC service software.
The BDI provides full functionality when used with
a full range of batteries including: HOURMETER
• Flooded cell, standard amp-hour batteries
• Flooded cell, high amp-hour capacity batteries There are three different hourmeter functions.
• Valve regulated (absorbed glass mat) maintenance- 1. Pump hours - accumulates time only when the
free batteries (VRLA) pump motor is operating.
2. Traction hours - accumulates time when the seat
switch is closed and the key switch is in the ON
position.
3. Secure hours - based on traction hours. The se-
cure hours cannot be reset.
The hourmeter data is stored in the master controller

during every 6 minutes of operation. If there is a loss
of power, data is not lost.
1. 4 SEGMENTS ADJACENT TO RED STATUS CODE LIST
2. 4 SEGMENTS ADJACENT TO ORANGE
3. 12 SEGMENTS ADJACENT TO GREEN The status code list is a stored history of selected sta-
4. BDI SHOWS APPROXIMATELY 65-70% CHARGE
tus codes for malfunctions or incorrect truck use that
Figure 15. Battery Discharge Indication in have occurred since the list was last cleared of entries
Dash Display LCD Window by a technician. These selected status codes are NOT
a list of malfunctions or symptoms that are currently
The lift interrupt feature is controlled by the vehicle present, but a list of those that have occurred in the
master controller and prevents the lift function when past. The list can only be read with the key in the
the battery is 80 percent discharged. Although lift in- OFF position.
terrupt prevents lifting, low speed functions, such as
tilt, remain operational to allow the operator to more To access the status code list, wait until after the
easily remove the forks from the load and return to traction and pump hours have been displayed, then
the battery charging area. push the STAR button. All of the status codes in the
list will then be shown in sequence. After the last
When lift interrupt is initiated, it will remain in ef- status code, END FAULT CODE HISTORY will be
fect until the battery is disconnected and a recharged shown.
16
2200 SRM 1087 Dash Display Service Menu Navigation
Dash Display Service Menu Navigation

GENERAL reached. To return to a previous menu item,
press the [1] key. When the last menu item is
To enter the service mode, turn the key to the ON po- reached and the [2] key is pressed again, the first
sition and press the (*) button twice. Enter Password menu item will return to the display.
prompt will appear on the display. See Figure 16. All
lift trucks will have 55555 as the default service pass- 2. To move into a submenu of a main menu item,
word at the time of delivery. This password can be press the [4] key on the dash display numeric key
changed by a service technician. Go to Editing and pad. To move into a sub submenu, as with the
Adding Information. Diagnostics menu, press the [4] key again.
3. To move up or down within the submenu or the

sub submenu, press the [1] or [2] keys.
4. To move out of the sub submenu and return to

the submenu, press the [3] key.
5. To move out of the submenu and return to the

main menu, press the [3] key.
Figure 16. Password Prompt 6. To exit the service mode, press the [3] key.
Buttons [1], [2], [3], [4], and [*] are used for menu EDITING AND ADDING INFORMATION
navigation and for adding or editing information.
Button [5] is only used if it is part of the password NOTE: The setup and password menus can be used to
required to enter the service mode. The display edit or add information to the truck software. When
has arrows on the buttons to aid in the navigation an item in these menus is selected, the current value
process. See Figure 17. will be displayed. The characters available to be se-
lected from the display are 0-9, A-Z, blank, and dash.
Each line in the display can have no more than 20
characters including blanks.
1. If a change is to be made, press the [4] key and

the cursor will blink on one of the characters.
Keys [3] and [4] are used to move from character
to character in the item being changed.
Figure 17. Dash Display Buttons
2. When a character that is to be changed is blink-
The following list is the numbers on the dash display ing, use keys [1] and [2] to scroll up or down until
and their function: the desired character is found. Use keys [3] or [4]
1. Is up, for scrolling up to move to the next character to be changed. This
2. Is down, for scrolling down is repeated until all changes in the item have
3. Is left, for scrolling left or out of the current menu been made.
4. Is right, for scrolling right or deeper into the next
3. When all changes have been made, press the [*]
menu level
key to store the value. Press the [1] or [2] key to
access the next item to be changed. Repeat this
MOVING THROUGH MENU SELECTIONS
procedure for each item that is to be changed.
1. When the service technician’s password is cor-
4. When all changes have been made, press the [3]
rectly entered, the first menu item, which is the
key to exit the menu.
hourmeter, is displayed on the dash display LCD
screen. To view the next menu item, press the
[2] key on the dash display numeric key pad. Re-
peat this until the desired menu item has been
17
Troubleshooting
GENERAL Tools and test equipment required are: clip leads,
volt ohmmeter (20,000 ohms per volt), and basic hand
The AC motor and master controllers are sealed tools.
units with no serviceable components. Troubleshoot-
ing is usually limited to accessing status codes and Check resistance on RX1000 scale from frame to
following the diagnostic procedures listed in the power and controller terminals. Resistance of less
Status Code Charts. than 20,000 ohms can cause misleading symptoms.
Resistance of less than 1000 ohms should be cor-
Use standard testing procedures to verify inputs and rected first.
outputs when necessary.
Before proceeding, visually check for loose wiring,
misaligned linkage to the accelerator switch, signs
CAUTION of overheating of components, etc.
Never attempt to probe through the back of
the connector plugs of the motor controller. STATUS CODES
These plugs are special sealed plugs. Probing
through the back of the plugs will destroy the NOTE: Make sure the parameter values are correct
seal and can cause a short circuit. If a circuit for your lift truck to ensure the trouble is not just an
must be tested for voltage, check for voltage at incorrect setting. See Function Parameters to set the
an amp-type plug, a switch, or a component. If correct parameter values. If there is no status code
a circuit is suspect, check the circuit for conti- display and the lift truck does not operate correctly,
nuity by disconnecting the P plug and testing there can be a fault in the master controller.
continuity from the front (pin end) of the plug.
The status codes are code numbers for malfunctions
Standard probes are too large to be inserted or lift truck operations that are not correct and that
into the center of the female pins (sockets) of the motor controller can sense. The master controller
the special sealed plugs and can expand the will indicate this code number on the LCD screen of
pins. Expanded pins will not provide good con- the display panel.
nections once the plug is reconnected.
The master and motor controllers sense the following
See the section Diagrams for your lift truck model types of malfunctions:
for additional wiring details. • Input voltages that are too high or too low
• Input voltages in the wrong sequence or
If the lift truck does not operate correctly, a status • Correct input voltages that occur at the wrong time
code is displayed on the display panel.
NOTE: A status code indication does not always mean
Once the status code number is obtained, follow the that there is a malfunction. A temporary operating
procedures outlined in the Status Code Charts of this condition can cause a status code display.
manual to determine the problem.
These code numbers are only codes to help identify
NOTE: Due to the interaction of the controller with a possible malfunction. A short description of the
all lift truck functions, almost any status code or con- different status codes is shown in Table 4.
troller fault could be caused by an internal failure of
the controller. After all other status code procedures The Status Code Charts in this section have a more
have been followed and no problem is found, the con- complete description of the status code, the circuit
troller should be replaced as the last option to correct that has generated the input for the status code, the
the problem. symptom, and the possible causes.
18
Table 4. List of Status Codes
Status Description Status Code Description

Code
01 Request traction or hydraulic 214L Wrong voltage on one phase --> failure
function while seat switch open. in power section (high leg), driver
circuit, or motor in slave controller.
02 Forward switches closed at key on. 214R Wrong voltage on one phase --> failure
in power section (high leg), driver
circuit, or motor in master controller.
03 Reverse switches closed at key on. 215L Wrong voltage on one phase --> failure
in power section (low leg), driver
circuit, or motor in slave controller.
05 Start switch not closed when seat 215R Wrong voltage on one phase --> failure
switch is closed and either the in power section (low leg), driver
forward or reverse directional circuit, or motor in master controller.
switch is closed and accelerator
voltage shows demand for traction.
06 Request traction function while 222 Controller checks to ensure main
forward and reverse switches are contactor coil or brake coil is not
opened. shorted at start up.
07 Accelerator input voltage too high 223 Controller checks main contactor tips
on power up. and ensures they are open before
powering controller.
08 Accelerator input voltage too low 224 Main contactor not closed.
on power up.
09 Forward and reverse direction 226 Electric brake driver damaged
requested together. (shorted or open).
10 Steer sensor feedback voltage too 227 Traction controller receives a
high. signal for traction from accelerator
potentiometer without start switch
being closed.
11 Start switch closed before key or 228 Pump contactor not connected or coil
seat switch. opened.
12 Steer sensor feedback voltage too 238 Internal failure of traction controller
low. hardware.
14 After steer calibration, controller 239 Master controller detected problem in
senses "max right" parameter to be slave controller functionality.
less than "max left" parameter.
15 Battery voltage lower than the 240 Slave controller detected problem in
setting in controller. the master controller functionality.
16 Battery voltage higher than the 241 Master does not see CAN messages
setting in controller. from slave.
19
Table 4. List of Status Codes (Continued)
41 High temperature in master or 242 Master does not see CAN messages
slave or both power sections, from electro-hydraulic lever console.
performance is progressively
reduced as temperature rises.
42 Pump control temperature too high. 243 Slave does not see CAN messages
from valve driver module.
43L Left traction motor temperature 244 Failure of dash display memory.
out of range.
43R Right traction motor temperature 245 Master does not see CAN messages
out of range. from display.
51 Capacitor voltage too low. 246 Slave does not see CAN messages
from display.
52L Failure in encoder, in encoder 247 Valve driver does not see CAN
to controller connection, or in messages from display.
controller input circuit, left motor.
52R Failure in encoder, in encoder 248 Slave does not see CAN messages
to controller connection, or in from master.
controller input circuit, right motor.
62 Backup alarm driver shorted. 249 No communication from slave to EV.
Overcurrent protection activated.
65 Main line contactor coil driver 250L Left rotor locked.
shorted.
66L Left traction motor shorted. 250R Right rotor locked.
66R Right traction motor shorted. 260 Incorrect voltage on pump motor
--> failure in power section, driver
section, or motor itself.
90L Left traction motor high 270 Error in lift/lower lever.
temperature.
90R Right traction motor high 271 Error in tilt lever.
temperature.
91 Pump motor high temperature. 272 Error in 3rd function lever.
95 Pump motor brushes worn. 273 Error in 4th function lever.
99 Maintenance required. 275 Internal failure of valve driver
module.
145 Power transistor did not turn on 276 One of the EV drivers of group 1
properly. (lift/lower) is shorted.
201 Request hydraulic or traction 277 One of the EV drivers of group 2
function while arm rest switch not (auxiliary in/out) is shorted.
closed.
202 Hydraulic oil low. 279 One of the EV drivers of group 3 (tilt
up/down) is shorted.
20
Table 4. List of Status Codes (Continued)
203 Brake fluid low. 280 One of the EV drivers of group 4

(sideshift R/L) is shorted.
204 Request traction or hydraulic 281 Driver of single EV (9th) is shorted.
function while hood switch/switches
not closed.
207 Lift cutout. 282 One of the on/off EV drivers is shorted.
208 Pump incorrect start. 283 One of the on/off EV coils is shorted;
short-circuit protection is triggered.
209L Brake coil open, disabling traction. 289 Voltage supply to the valve driver
control module is low.
209R Brake coil open, disabling traction. 292 Battery selection is wrong in valve
controller.
210 Internal "watchdog" hardware 294 Interlocked hydraulic function
circuit triggered. requested without activation of
interlock switch.
213 The controller has detected an 295 Hi-Lift switch is closed and the Lo-Lift
overvoltage or an undervoltage switch is open.
condition within the controller.
Status Premium Display Message Memory Recall Circuit

Code
01 NO SEAT SWITCH INPUT No Traction
Description
Controller is not receiving an input signal from
the seat switch while receiving a traction or
hydraulic function command.
Symptom
Lift truck does not move.
Probable Causes and Test Procedures
• Seat switch malfunction.
Check to see if the seat switch operates prop-
erly.
Use the dash display diagnostics menu to
check the seat switch operation.
Replace failed switch.
• Check continuity of wiring to and from the seat
switch to the traction controller.
Pin C33 at motor controller to seat switch.
Seat switch to Pin C18 at motor controller.
21

Code
02 FORWARD SWITCH CLOSED No Traction
Description
Forward directional switch is closed before the
key switch closes.
Symptom
• A directional switch is engaged before startup.
Return directional switch to neutral.
• A directional switch is failed, closed, or out of
adjustment.
Use dash display diagnostics menu to check
operation of the directional switches.
Adjust switch for correct operation. See the
section Electrical System 2200 SRM 1078.
22

Code
03 REVERSE SWITCH CLOSED No Traction
Description
Reverse directional switch is closed before the key
switch closes.
Symptom
• A directional switch is engaged before startup.
Return directional switch to neutral.
• A directional switch is failed, closed, or out of
adjustment.
Use dash display diagnostics menu to check
operation of the directional switches.
Adjust switch for correct operation. See the
section Electrical System 2200 SRM 1078.
23

Code
05 START SWITCH NOT CLOSED No Traction
Description
Start switch is open when the seat switch is closed
and either the forward or reverse directional
switch is closed and the accelerator output voltage
shows there is a demand for traction.
Symptom
• Malfunction of the start switch.
Use dash display diagnostics to check opera-
tion of the start switch.
Check for proper switch adjustment.
Replace start switch.
Check for open circuit or loose connections in
wiring from the key switch to the start switch
and from the controller to the start switch.
24

Code
06 NO DIRECTION SELECTED No Traction
Description
The forward and the reverse switches are both
open and there is a request for traction.
Symptom
• Accelerator pedal is depressed before closing a
directional switch.
Status code will disappear when the pedal is
released.
• Open circuit between the directional switch and
the controller.
Use dash diagnostics to check the operation of
the switch.
Check wiring from C4 to FWD and REV
switches.
Check wiring from switches to C6 and C7.
Check operation of switch for continuity
through the switch when the switch is closed.
• Malfunction of the directional switch.
Check switch adjustment.
FWD or REV switch is closed when direc-
tion is selected.
25

Code
07 THROTTLE POT ERROR Yes Traction
Description
Accelerator input voltage is too high when the key
is first moved to the ON position.
Symptom
• Accelerator unit has a malfunction or is out of
adjustment.
Maximum accelerator wiper voltage should be
4.6 volts with the pedal fully up at C33.
Check for open circuit between accelerator
and controller.
Recalibrate throttle. See the section Electri-
cal System 2200 SRM 1078.

Code
08 THROTTLE VOLTAGE LOW No Traction
Description
Accelerator input voltage is too low when the key
is first moved to the ON position.
Symptom
• Accelerator unit has a malfunction or is out of
adjustment.
Check for open circuit between accelerator
and controller.
Minimum accelerator wiper voltage should be
0.5 volt with the pedal fully down at C21.
26

Code
09 FWD and REV SWITCHES No Traction
CLOSED AT SAME TIME
Description
Both the forward and reverse directional switches
are closed at the same time.
Symptom
• Either the forward or reverse switch is failed
closed.
Use dash display diagnostic to check operation
of directional switches.
Replace failed or malfunctioning switch.
• Directional switch is out of adjustment.
Switches should be open with directional
switch in neutral.
27

Code
10 STEER SENSOR VOLTAGE HIGH Yes Traction
Description
Steer sensor feedback voltage is too high.
Symptom
• Use dash diagnostics to check operation of the
steer sensor.
• Check potentiometer and adjustment. Poten-
tiometer wiper should be set at 5K ohms with
wheels straight ahead.
• Check wiring continuity between steering poten-
tiometer and traction controller.
• Check voltage between C15 and C16.
Voltage should be 5.0 volts.
• Recalibrate steering. See the section Electrical
System 2200 SRM 1078.
28

Code
11 START SWITCH CLOSED No Traction
BEFORE KEY
Description
Accelerator start switch is closed before the key
and/or the seat switch.
Symptom
• Accelerator pedal depressed when key is turned
to ON position.
Release pedal and restart.
• Accelerator start switch is out of adjustment.
Switch should be open with accelerator pedal
fully up.
• Accelerator start switch is shorted closed.
Use dash display diagnostic menu to check op-
eration of switch.
29

Code
12 STEER SENSOR VOLTAGE LOW Yes Traction
Description
Steer sensor feedback voltage is too low.
Symptom
• Use dash diagnostics to check operation of the
steer sensor.
• Check potentiometer and adjustment. Poten-
tiometer wiper should be set at 5K ohms with
wheels straight ahead.
• Check wiring continuity between steering poten-
tiometer and traction controller.
• Check voltage between C15 and C16.
Voltage should be 5.0 volts.
• Recalibrate steering. See the section Electrical
System 2200 SRM 1078.

Code
14 WRONG STEER CALIBRATION Yes Traction
Description
After steer calibration, the controller is sensing
the "max right" parameter to be less than the
"max left" parameter.
Symptom
No lift truck operation.
• Recalibrate the steering sensor.
• Check sensor values using the dash diagnostics.
• Check adjustment of the steering potentiometer.
• Check for 5.0-volt supply voltage at the steering
potentiometer.
30

Code
15 BATTERY VOLTAGE LOW Yes Traction
Description
The battery voltage is lower than the setting in
the controller.
Symptom
• Discharged battery.
Check battery for correct open circuit voltage.
Charge battery.
• Battery is damaged.
Check each cell for correct voltage (greater
than 1.85 volts per cell).
Repair or replace battery.
• Incorrect controller adjustment.
Use dash display to check battery voltage.
• Incorrect battery installed in truck.

Code
16 BATTERY VOLTAGE HIGH Yes Traction
Description
The battery voltage is higher than the setting in
the controller.
Symptom
• Overcharged battery.
Check battery for correct open circuit voltage.
• Incorrect controller adjustment.
Use dash display to check battery voltage.
• Incorrect battery installed in truck.
31

Code
41 TRACTION CONTROL Yes Traction
TEMPERATURE HIGH
Description
High temperature in the traction controller power
section. Truck performance is progressively
reduced as temperature rises.
Symptom
Traction performance is reduced.
• Reduce duty cycle until temperature is reduced.
• If fault is indicated when controller is cold, re-
place controller.

Code
42 PUMP CONTROL TEMPERATURE Yes Hydraulic
HIGH
Description
Pump controller temperature is too high.
Traction performance is progressively reduced as
temperature increases.
Symptom
• Reduce duty cycle until temperature is reduced.
• If fault is indicated when controller is cold, re-
place controller.
32

Code
43L LEFT MOTOR TEMP OUT Yes Traction
OF RANGE
Description
Left traction motor temperature is out of range.
Symptom
• Ensure all wiring connections are tight.
• Failed thermal sensor in traction motor.
Using dash display diagnostic, check motor
temperature.

Code
43R RIGHT MOTOR TEMP OUT Yes Traction
OF RANGE
Description
Right traction motor temperature is out of range.
Symptom
• Ensure all wiring connections are tight.
• Failed thermal sensor in traction motor.
Using dash display diagnostic, check motor
temperature.
33

Code
51 PRECHARGE Yes Traction
Description
Controller capacitor voltage does not increase at
startup.
Symptom
• Remove fuse FU3 and turn key to the ON posi-
tion. If problem remains, replace controller.
• Ensure towing jumper has been disconnected
near dash display.
• Ensure dash display is operating properly.
• Failed R1 resistor in the steering circuit.
• Check for brake driver continuous ON.
With the key in the ON position, check for
voltage between pins C28 and C29.
Replace controller.
• Failure of the controller logic card.
Replace controller.

Code
52L LEFT ENCODER ERROR Yes Traction
Description
Incorrect feedback from traction motor speed
sensor.
Symptom
• Use dash diagnostics to check encoder operation.
• Check for 12-volt supply to encoder.
• Ensure wiring to the encoder is correct. See the
section Diagrams 8000 SRM 1081.
• Ensure all wiring connections between the en-
coder and the traction motor are tight.
• Check continuity of the wiring from the con-
troller to the encoder.
• Replace traction motor end head.
34

Code
52R RIGHT ENCODER ERROR Yes Traction
Description
Incorrect feedback from traction motor speed
sensor.
Symptom
• Use dash diagnostics to check encoder operation.
• Check for 12-volt supply to encoder.
• Ensure wiring to the encoder is correct. See the
section Diagrams 8000 SRM 1081.
• Ensure all wiring connections between the en-
coder and the traction motor are tight.
• Check continuity of the wiring from the con-
troller to the encoder.
• Replace traction motor end head.
35

Code
62 REVERSE SIGNAL OUTPUT Yes Auxiliary
SHORTED
Description
Backup alarm driver is shorted. Overcurrent
protection has been activated.
Symptom
Backup alarm does not operate.
• Ensure all wiring is secure.
• Check wiring for shorts.
• Check for a shorted alarm.
• Replace dash display.
36

Code
65 MAIN CONTACTOR SHORTED Yes Traction
Description
The main contactor coil driver is shortened.
Symptom
• Check for shorted driver at the controller. Check
for short between terminal C26 and B .
• Check for shorted main contactor coil. Coil
should measure approximately 32 ohms.
• Failure of the controller logic card. Replace the
controller.
37

Code
66L LEFT TRACTION MOTOR Yes Traction
SHORTED
Description
Left traction motor is shorted.
Symptom
• Disconnect all motor leads from the traction mo-
tor.
• Check line-to-line stator resistance. Resistance
should be 10.00 ±0.10 milliohms for 48-volt truck
and 6.10 ±0.10 milliohms for 36-volt truck.
• Replace traction motor if readings are not cor-
rect.
38

Code
66R RIGHT TRACTION MOTOR Yes Traction
SHORTED
Description
Right traction motor is shorted.
Symptom
• Disconnect all motor leads from the traction mo-
tor.
• Check line-to-line stator resistance. Resistance
should be 10.00 ±0.10 milliohms for 48-volt truck
and 6.10 ±0.10 milliohms for 36-volt truck.
• Replace traction motor if readings are not cor-
rect.
39

Code
90L LEFT TRACTION MOTOR Yes Traction
TEMP HIGH
Description
Left traction motor high temperature.
Temperature sensor in traction motor has
indicated high temperature.
Symptom
• Use dash display diagnostics to verify motor
over-temperature switch is activated.
Reduce truck operation until motor cools.
• If a fault is signaled with cold motor, check the
motor temperature sensor resistance. Resis-
tance should be 555 ohms to 607 ohms at 20 C
(68 F).
• Check for broken or loose wires.

Code
90R RIGHT TRACTION MOTOR Yes Traction
TEMP HIGH
Description
Right traction motor high temperature.
Temperature sensor in traction motor has
indicated high motor temperature.
Symptom
Reduce truck operation until motor cools.
• If a fault is signaled with cold motors, check
the motor temperature sensor resistance. Resis-
tance should be 555 ohms to 607 ohms at 20 C
(68 F).
• Check for broken or loose wires.
40

Code
91 PUMP MOTOR TEMPERATURE No Lift
HIGH
Description
Pump motor temperature too high. Thermal
switch in pump motor has been activated.
Symptom
Display message.
• Reduce truck operation until motor cools.
• If fault is signaled with cold motor, use dash dis-
play diagnostic to verify motor temperature.
Replace motor temperature sensor.
Replace dash display.
41

Code
95 PUMP MOTOR BRUSHES No Lift
Description
Pump motor brushes worn. Brush wear indicator
switch in pump motor has been activated.
Symptom
Dash display message.
• Replace pump motor brushes.
• Check wiring.
• If brushes are OK, replace dash display.

Code
99 MAINTENANCE REQUIRED No None
Description
Truck maintenance required.
Symptom
Dash display message. Flashing "wrench" icon.
• Truck requires scheduled maintenance.
• Perform required maintenance activity.
42

Code
145 PUMP M- FAULT Yes Hydraulic
Description
Power transistor did not turn on properly.
Symptom
No lift operation.
• Check wiring connections between the controller
and the pump motor.
• Check for open motor windings.
• Check for worn pump motor brushes.

Code
201 NO ARM REST SWITCH INPUT No Lift
Description
Arm rest switch not closed when requesting
traction or hoist functions.
Symptom
Lift does not operate.
• Ensure arm rest is in full down position.
Arm rest should be in the locked position.
• Use dash diagnostics to check operation of
switch.
Check all wiring connections to switch.
Check switch adjustment. See the section
Electrical System 2200 SRM 1078 for ad-
justment procedure.
43

Code
202 HYDRAULIC OIL LOW No Lift
Description
Hydraulic fluid is low.
Symptom
Dash display message. Flashing icon on display.
• Ensure forks are fully lowered, turn key to the
ON position.
• Check hydraulic fluid level.
Add fluid. See the section Periodic Mainte-
nance 8000 SRM 1079 for correct fluid.
• Check sensor for open condition.
Ensure all wiring connections are secure.
Replace sensor.
Replace dash display.
44

Code
203 BRAKE FLUID LOW No Brake
Description
Brake fluid is low.
Symptom
Dash display message. Flashing icon on display.
• Check brake master cylinder fluid level. Fill as
needed.
• Check for loose or broken wires.
CAUTION
Do not use DOT brake fluid! This truck uses
hydraulic oil in the brake system. See the
section Capacities and Specifications 8000
SRM 1080.
• Check sensor.
Disconnect wiring connector.
Remove fill cap and sensor from reservoir.
Check resistance across the sensor pins.
Resistance is approximately 470 ohms
when float is fully raised.
Resistance is less than 10 ohms when the
float is fully lowered and the switch is
closed.
45

Code
204 NO HOOD SWITCHES INPUT No Traction/Lift
Description
Hood switch or switches are open when requesting
traction or hydraulic functions.
Symptom
No traction or lift operation.
• Ensure all wiring connections are secure.
• Check wiring continuity between switches.
There are two switches wired in series.
Check for voltage at C5 with both switches
closed.
Check each switch for open condition while op-
erating the switch.
• Replace failed switch.
46

Code
207 LIFT INTERRUPT No Lift
Description
Fault is set when battery is discharged below 20
percent of full charge.
Symptom
• Occurs when battery is 80 percent discharged.
• Discharged battery.
Charge or change battery.

Code
208 PUMP REQUEST BEFORE KEY No Lift
Description
Incorrect pump motor starting sequence.
Symptom
Manual Valve
• Recycle key.
• Check for a closed hydraulic function switch at
the manual hydraulic control valve.
Check switch adjustment.
Switches should be open with the hydraulic
function levers in the neutral position.
• Replace failed switch.
Electro-Hydraulic Valve
• Cycle key switch from OFF to ON.
• Check for function lever not in neutral. See
the section Electro-Hydraulic Control Valve
2000 SRM 1086.
• Replace failed function lever.
47

Code
209L BRAKE COIL OPEN No Brake
Description
Brake coil is open, disabling traction.
Symptom
No truck movement, or truck may pull to one side
when starting to accelerate.
• Electric brake will not release.
Recycle key switch.
• Check for voltage at the brake coil.
Should read approximately 36 volts.
• If no voltage, check wiring for loose connection or
broken wire.
• Check motor encoder. See Status Code 52.
• Check brake circuit diodes.
48

Code
209R BRAKE COIL OPEN No Brake
Description
Brake coil is open, disabling traction.
Symptom
No truck movement, or truck may pull to one side
when starting to accelerate.
• Electric brake will not release.
Recycle key switch.
• Check for voltage at the brake coil.
Should read approximately 36 volts.
• If no voltage, check wiring for loose connection or
broken wire.
• Check motor encoder. See Status Code 52.
• Check brake circuit diodes.
49

Code
210 WATCHDOG IN TRACTION Yes Traction
CONTROLLER
Description
The internal "watchdog" hardware circuit has
been triggered.
Symptom
• Check resistance between CANL and CANH
wires at the controller.
Resistance should be approximately 60 ohms.
• Replace the controller.

Code
213 UNDER/OVER VOLTAGE Yes Internal Controller
Description
The controller has detected an overvoltage or an
undervoltage condition within the controller.
Symptom
• Fault in the hardware section of the logic card.
• Replace the controller.
50

Code
214L LEFT MOTOR VOLTAGE LOW Yes Traction
Description
Incorrect voltage on one phase of the power
circuit.
Symptom
• Check all wiring connections to motors and con-
troller. All connections should be tight.
• Ensure power wires are connected to correct ter-
minals. See the section Diagrams 8000 SRM
1081.
• Check for traction motor grounded to frame.
• Fault in the inverter section of the controller.
Replace the controller.

Code
214R RIGHT MOTOR VOLTAGE LOW Yes Traction
Description
circuit.
Symptom
1081.
51

Code
215L LEFT MOTOR VOLTAGE HIGH Yes Traction
Description
circuit.
Symptom
1081.

Code
215R RIGHT MOTOR VOLTAGE HIGH Yes Traction
Description
circuit.
Symptom
1081.
52

Code
222 MAIN OR BRAKE COIL Yes Traction
OVERCURRENT
Description
The controller checks to ensure the main contactor
or brake coils are not shorted at start up.
Symptom
• Check for shorted main contactor coil. Coil
should measure approximately 32 ohms resis-
tance across the coil terminals.
• Check for shorted wiring.
• Failure of the controller logic card. Replace the
controller.
• Check for shorted brake coils. Coil should mea-
sure 32.5 ohms resistance across the coil leads.

Code
223 MAIN CONTACTOR WELDED Yes Traction
Description
The controller checks the main contactor tips
and ensures they are open before powering the
controller.
Symptom
• Check that the main contactor tips are not
welded.
• Open contactor tips and replace if needed.
53

Code
224 MAIN CONTACTOR NOT CLOSED Yes Traction
Description
The controller checks to ensure the main contactor
closes after power has been supplied to the
contactor coil.
Symptom
• Ensure contactor is not stuck in open position.
• Open contactor coil. Check the contactor coil.
Coil should measure approximately 32 ohms re-
sistance.
• Check wiring from the controller to the contactor
coil. Check for continuity from C26 to coil. Check
for continuity from C27 to coil.
54

Code
226 BRAKE DRIVER OPEN OR Yes Traction
SHORTED
Description
Internal check of the parking brake driver in the
controller.
Symptom
• Disconnect connector C from controller.
Check for short between B and C28.
The brake coil resistance is approximately 31
ohms.
55

Code
227 THROTTLE VOLTAGE HIGH No Traction
Description
The traction controller is receiving a signal for
traction from the accelerator potentiometer
without the start switch being closed.
Symptom
• Accelerator potentiometer is out of adjustment.
Use dash display diagnostics to check opera-
tion of the start switch.
Check for proper switch adjustment.
• Replace throttle sensor.

Code
228 PUMP CONTACTOR OPENED No Lift
Description
Lift contactor is not connected or coil is open.
Symptom
Lift does not operate on trucks equipped with
contactor lift.
• Ensure all wiring is secure.
• Check for continuity between C30 and contactor
coil.
• Check for continuity between C31 and contactor
coil.
• Check coil resistance. Resistance should mea-
sure approximately 15 ohms.
• Replace contactor coil.
56

Code
238 TRACTION CONTROLLER FAULT Yes/No Traction
Description
Internal failure of the traction controller
hardware.
Symptom
Lift truck will not operate.
• Recycle key from OFF to ON.
If fault repeats, replace controller.

Code
239 ALARM IN SLAVE Yes Internal Controller
Description
Master controller has detected a problem with the
slave controller.
Symptom
Lift truck does not operate.
• Internal failure of the traction controller. Re-
place controller.
57

Code
240 ALARM IN MASTER Yes Internal Controller
Description
Slave controller has detected a problem with the
master controller.
Symptom
Lift truck does not operate.
place controller.

Code
241 NO COMMUNICATION SLAVE Yes Internal Controller
TO MASTER
Description
Master controller is not receiving CAN messages
from the slave controller.
Symptom
place controller.
58

Code
242 NO COMMUNICATION LEVER Yes Lift
TO MASTER
Description
from the electro-hydraulic lever console.
Symptom
• Ensure all wiring connections to the lever con-
sole are secure.
• Check continuity of the CAN bus wires between
the dash display and the controller.
• Check for 12 volts between wire 74 and wire 130
at the lever console.
Check for 12 volts between B10 and B3 at the
valve driver module.
• Check for 60 ohms resistance between
CANH_OUT and CANL_OUT.
• Replace lever console.
59

Code
243 NO COMMUNICATION EV Yes Lift
TO SLAVE
Description
Slave controller is not receiving CAN messages
from the electro-hydraulic valve driver module.
Symptom
• Ensure all wiring connections to the lever con-
sole are secure.
• Check for 60 ohms resistance between
CANH_OUT and CANL_OUT.
• Replace the valve driver module.
EV = Electro-hydraulic valve driver module.

Code
244 DASH DISPLAY FAULT No Display
Description
Failure of the dash display memory.
Symptom
Dash display does not operate.
• Ensure battery is connected to the truck.
• Turn key to the ON position.
• Replace dash display.
60

Code
245 NO COMMUNICATION MASTER Yes Traction
TO DASH
Description
from the dash display.
Symptom
Lift truck does not move or moves very slowly.
• Check termination resistor. Should measure ap-
proximately 60 ohms between A7 and A22 at the
dash display.
61

Code
246 NO COMMUNICATION SLAVE Yes Traction
TO DASH
Description
from dash display.
Symptom
dash display.
62

Code
247 NO COMMUNICATION EV Yes Lift
TO DASH
Description
Electro-hydraulic valve driver module is not
receiving CAN messages from the dash display.
Symptom
the dash display and the valve driver module.
dash display.

Code
248 NO COMMUNICATION MASTER Yes Internal Controller
TO SLAVE
Description
from the master controller.
Symptom
• Reset key to the ON position.
• Replace controller.
63

Code
249 NO COMMUNICATION SLAVE Yes Internal Controller
TO EV
Description
EV controller is not receiving CAN messages from
the slave controller.
Symptom
Truck will not operate.
• Reset key to the ON position.
• Replace controller.

Code
250L LEFT ROTOR LOCKED Yes Traction
Description
The controller is supplying current to the traction
motors while sensing one or both of the traction
motors is not turning.
Symptom
No truck movement while depressing the
accelerator pedal.
• Wheel is in a hole and the truck cannot move.
• Brake coil has not released the brake disk.
• Mechanical failure of one or both of the traction
motors.
64

Code
250R RIGHT ROTOR LOCKED Yes Traction
Description
The controller is supplying current to the traction
motors while sensing one or both of the traction
motors is not turning.
Symptom
No truck movement while depressing the
accelerator pedal.
• Wheel is in a hole and the truck cannot move.
• Brake coil has not released the brake disk.
• Mechanical failure of one or both of the traction
motors.

Code
260 PUMP MOTOR VOLTAGE LOW Yes Transistor Lift
Description
Incorrect voltage on pump motor.
Symptom
No lift operation.
• Wrong voltage battery installed in truck.
Ensure battery voltage matches voltage
shown on truck nameplate.
• Wrong voltage parameter selection.
Ensure parameter setting matches voltage
shown on truck nameplate.
Check parameter setting using the dash dis-
play.
65

Code
270 LIFT/LOWER LEVER ERROR Yes Electro-hydraulic
Description
Error in signal from the lift/lower lever assembly.
Symptom
No lift/lower operation.
• Check for 12 volts at pin 1 on the hydraulic lever
console.
Check for 12 volts at pin B10 on the valve
driver module.
Replace the valve driver module.
• Replace the lift/lower lever PC board.

Code
271 TILT LEVER ERROR Yes Electro-hydraulic
Description
Error in the signal from the tilt lever.
Symptom
No mast tilt operation.
console.
driver module.
• Replace the tilt lever PC board.
66

Code
272 3RD FUNCTION LEVER ERROR Yes Electro-hydraulic
Description
Error in the signal from the sideshift lever.
Symptom
No carriage sideshift operation.
console.
driver module.
• Replace the sideshift lever PC board.

Code
273 4TH FUNCTION LEVER ERROR Yes Electro-hydraulic
Description
Error in the signal from the auxiliary lever.
Symptom
No operation of the auxiliary hydraulic function.
console.
driver module.
• Replace the auxiliary lever PC board.

Code
275 VALVE CONTROLLER FAULT Yes Electro-hydraulic
Description
Internal failure of the valve driver module.
Symptom
No operation of the electro-hydraulic functions.
• Recycle key switch from OFF to ON.
• Replace the valve driver module.
67

Code
276 LIFT/LOWER EV DRIVER Yes Electro-hydraulic
SHORTED
Description
Lift/lower driver in the valve driver module is
shorted.
Symptom
No lift/lower operation.
• Recycle key switch to clear fault.
• Disconnect connector from EV. Check wires for
shorts to B- or between wires.
• Check resistance of coils:
Resistance should read approximately 19
ohms at 25 C (77 F).
• Replace valve driver module.
68

Code
277 4TH FUNCTION EV DRIVER Yes Electro-hydraulic
SHORTED
Description
Auxiliary driver in the valve driver module is
shorted.
Symptom
No operation of the auxiliary hydraulic function.
69

Code
279 TILT EV DRIVER SHORTED Yes Electro-hydraulic
Description
Tilt driver in the valve driver module is shorted.
Symptom
No tilt function operation.
70

Code
280 3RD FUNCTION EV DRIVER Yes Electro-hydraulic
SHORTED
Description
The sideshift function driver in the valve driver
module is shorted.
Symptom
No sideshift function operation.
71

Code
281 EV 9 DRIVER SHORTED Yes Electro-hydraulic
Description
Single EVP driver is shorted.
Symptom

This spare output is not used.
• Check the connector wiring.
• Replace EV if unable to clear fault.

EVP = Electro-hydraulic proportional valve driver.
72

Code
282 SELECTOR EV DRIVER SHORTED Yes Electro-hydraulic
Description
On/off EV driver is shorted.
Symptom

73

Code
283 SELECTOR EV COIL SHORTED Yes Electro-hydraulic
Description
One of the electro-hydraulic valve coils is shorted.
Symptom
One of the hydraulic functions will not operate.
74

Code
289 EV CONTROLLER LOW VOLTAGE Yes Electro-hydraulic
Description
Voltage supply to the valve driver control module
is low.
Symptom
No operation of the electro-hydraulic functions.
• Check for battery voltage at pins B1 and B2 with
key switch closed.
• Check that all connections are secure.
75

Code
292 WRONG BATTERY SET IN EV Yes Electro-hydraulic
CONTROLLER
Description
Incorrect battery selection parameter in the valve
driver module.
Symptom
No operation of hydraulic system.
• Ensure battery voltage matches voltage shown
on the lift truck nameplate.
Install correct voltage battery in the lift truck.
• Ensure battery parameter setting matches volt-
age shown on the lift truck nameplate.
Use dash display to change battery parameter.

Code
294 NO INTERLOCK SWITCH INPUT No Hydraulic
Description
Message is displayed when an interlocked
hydraulic function is requested without activating
the interlock switch.
Symptom
No operation of the requested interlocked
hydraulic function.
• Use the dash display diagnostics to turn off
the lever interlock parameter. If function now
operates, replace function lever with interlock
switch.
76

Code
295 NO LO LIFT SWITCH INPUT Yes Hydraulics
Description
Message is displayed when the hi-lift switch is
closed and the lo-lift switch is open.
Symptom
Lift will only operate at low speed.
• Use dash display diagnostics to check for correct
operation of the lo-lift switch.
• Check switch for correct operation.
• Check for correct switch adjustment. See the sec-
tion Electrical System 2200 SRM 1078 for ad-
justment procedure.
• Check wiring to switch for loose connections or
broken wires.
CONTROLLER CONNECTOR PIN OUTS Table 5. Connector A (Continued)
Table 5. Connector A
Pin Wire Function
Number
Pin Wire Function
Number A5
A1 CANH High Level CAN bus A6 CANL Low Level CAN bus
A2 A7 CANH-OUT High Level CAN bus
A3 A8
A4 CANL-OUT Low Level CAN bus
77
Table 6. Connector C Table 6. Connector C (Continued)
Pin Wire Function

Pin Wire Function
Number
Number
C1 83 Right Motor Encoder
C23 78 Left Motor Encoder
Positive (+5V/+12V)
Phase A
C24 82 Right Motor Temp
B
Sensor B
C3 10 B+ from Key Switch
C25 81 Right Motor Temp
C4 110 B+ to Switches Sensor Input Signal
C5 101 Seat Switch Input C26 23 Main Contactor B
C27 24 Main Contactor B+
C6 6 Forward Switch Input
C28 50 Parking Brake Coil B
C7 8 Reverse Switch Input
C29 51 Parking Brake Coil B+
C8 15 Start Switch Input
C30 88 Auxiliary B+
C9 92 Brake Pedal Switch
Input C31 87 Auxiliary B
C10 94 Hydraulic Function C32 B

Input (Contactor C33 28 Traction Potentiometer
Hydraulic Only) Positive (+5V/+12V)
C11 75 Left Motor Encoder C34 79 Left Traction Motor
Positive (+5V/+12V) Temp Sensor B
C12 76 Left Motor Encoder B C35 80 Left Traction Motor
C13 85 Right Motor Encoder Temp Sensor Input
Phase B Signal

Phase A Table 7. Connector D - Standard Model
C15 70 Steering Potentiometer
B Pin Wire Function
Number
C16 72 Steering Potentiometer
Positive (+5V/+12V) D1
C17 71 Steering Potentiometer D2 113 High Speed Lift Switch

Wiper Input Input
C18 104 Brake Potentiometer D3 98 Low Speed Lift Switch

Wipe Input Input
C19 103 B D4 114 Tilt Speed Prox Switch

Input
C20 27 Accelerator
Potentiometer B D5 210 B+ for Hydraulic
Switches
C21 29 Traction Potentiometer
Wiper Input D6 97 4th Function Speed
Switch Input
C22 77 Left Motor Encoder
Phase B D7 93 Sideshift Switch Input
D8 95 Tilt Switch Input
78
Table 7. Connector D - Standard Table 9. Connector B (Continued)

Model (Continued)
Pin Wire Function
Pin Wire Function Number
Number
B2 10-1 Key Switch Input B+
D9
B3 130 Battery Negative
D10
B4 CANL-2 CAN Low Input Signal
D11
B5 OPEN
D12
B6 OPEN
D13
B7 OPEN
D14
B8 OPEN
B9 OPEN
Table 8. Connector D - Premium Model
B10 74 12V Supply to Lever
Module
Pin Wire Function
Number B11 OPEN
D1 B12 OPEN
D2 B13 CANH-2 CAN High Input Signal
D3 B14 OPEN
D4 114 Tilt Speed Prox Switch
Input Table 10. Connector C
D5 210 B+ for Hydraulic
Switches Pin Wire Function
Number
D6
C1 53 Negative for Lowering
D7
Proportional Valve
D8
C2 52 Positive for Lift and
D9 Lower Proportional
Valves
D10
C3 54 Negative for Lift
D11
Proportional Valve
D12
C4 56 Negative for Auxiliary
D13 IN Proportional Valve
D14 C5 55 Positive for Auxiliary
Proportional Values
VALVE DRIVER MODULE C6 57 Negative for Auxiliary
(ELECTRO-HYDRAULIC VALVE OPTION) OUT Proportional
Valve
Table 9. Connector B
C7 59 Negative for Tilt UP
Pin Wire Function Proportional Valve
Number C8 58 Positive Voltage Supply
B1 10-1 Key Switch Input B+ for Tilt Proportional
Valves
79
Table 10. Connector C (Continued) DASH DISPLAY

Pin Wire Function
Pin Wire Function Number
Number
A1 10-1B Key Switch Input B+
C9 65 Negative for Load Hold
Valve A2 110-1 Positive Supply to
Indicators
C10 67 Negative for Tilt
Auxiliary Selector A3 130F Battery Negative B
Valve A4 130G Battery Negative B
C11 OPEN A5 107 Lift Motor Brush Wear
C12 62 Negative for Sideshift Indicator Input
Right Proportional A6 102 Negative for Pump
Valve Motor Temp Sensor
C13 61 Positive for Sideshift A7 CANL-1 CAN bus Low
Right and Left
Proportional Valves A8 OPEN
C14 63 Negative for Sideshift A9 90 Negative for Hydraulic

Left Proportional Valve Oil Lever Sensor
C15 60 Negative for Tilt Down A10 91 Positive for Brake Fluid
Proportional Valve Level Switch
C16 64 Positive for Lift Hold A11 96 Negative for Auxiliary

Valve Switch
C17 66 Positive for Tilt A12 50G Parking Brake Coil

Auxiliary Selector Input
Valve A13 50F Parking Brake Coil
C18 OPEN Input
C19 OPEN A14 OPEN
C20 OPEN A15 OPEN
C21 OPEN A16 47B Steering Encoder Input
C22 OPEN A17 12A Battery Positive B+
C23 130 Battery Negative A18 130P Battery negative B

A19 OPEN
HYDRAULIC LEVER CONSOLE A20 26 Positive for Reverse
(ELECTRO-HYDRAULIC OPTION Alarm
ONLY) A21 OPEN
Pin Wire Function A22 CANH-1 CAN bus High
Number
A23 OPEN
1 74 12V Supply from Valve
Driver Module
2 CANH_OUT1 CAN bus High
3 130 Battery Negative
4 CANL_OUT1 CAN bus Low
80
SYSTEM LOGIC DIAGRAMS

The system logic diagrams for the economy, stan-
dard, and premium truck models may be able to as-
sist in troubleshooting. See Figure 18, Figure 19, and
Figure 20.
Figure 18. Logic Diagram - Economy
81
Figure 19. Logic Diagram - Standard
82
Figure 20. Logic Diagram - Premium
83
NOTES
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84

INDUSTRIAL BATTERY
ALL ELECTRIC LIFT TRUCKS
PART NO. 899648 2240 SRM 1

SAFETY PRECAUTIONS

nance section.
manual:
WARNING
CAUTION
Industrial Battery Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Lead-Acid Batteries ........................................................................................................................................... 1
Specific Gravity .................................................................................................................................................. 2
Chemical Reaction in a Cell .............................................................................................................................. 2
Electrical Terms ................................................................................................................................................. 3
Battery Selection................................................................................................................................................ 4
Battery Voltage .................................................................................................................................................. 5
Battery as a Counterweight .............................................................................................................................. 5
Battery Ratings.................................................................................................................................................. 5
Kilowatt-Hours .............................................................................................................................................. 5
Battery Maintenance ......................................................................................................................................... 6
Safety Procedures .......................................................................................................................................... 6
Maintenance Records .................................................................................................................................... 6
New Battery ................................................................................................................................................... 6
Cleaning Battery ........................................................................................................................................... 7
Adding Water to Battery ............................................................................................................................... 8
Hydrometer .................................................................................................................................................... 9
Battery Temperature ..................................................................................................................................... 9
Charging Battery ........................................................................................................................................... 10
Types of Battery Charges.......................................................................................................................... 11
Methods of Charging ................................................................................................................................. 12
Troubleshooting Charger .......................................................................................................................... 13
Knowing When Battery Is Fully Charged ............................................................................................... 13
Where to Charge Batteries............................................................................................................................ 13
Equipment Needed .................................................................................................................................... 13
Battery Connectors........................................................................................................................................ 14
Battery Care .................................................................................................................................................. 14
All Electric Lift Trucks

"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
2240 SRM 1 Lead-Acid Batteries
General
This section describes how to select and do the main- batteries have a nameplate attached to the face of the
tenance for large batteries used in electric lift trucks. battery cover. This nameplate communicates specific
This information is for service personnel that must information about the battery including the name of
do the maintenance on large lead-acid batteries. Bat- the battery manufacturer, battery type, serial num-
tery repair requires special training and equipment. ber, nominal voltage, capacity in amperes at the five
Do not try to repair a battery unless you have the cor- hour rate, and service mass (with ballast if used to
rect tools, equipment, and experience. Most battery compensate for lack of battery mass).
repairs are done by a special repair service. Some
Lead-Acid Batteries
A lead-acid battery converts chemical energy into
electrical energy. See Figure 1. Chemical changes
within the battery give the electrical energy. When
the chemical reaction has occurred so the battery
will not give its rated voltage and current, the bat-
tery is discharged. A reverse chemical action must
occur so the battery can be used again. The batteries
described in this section can be charged again by an
electric voltage and current from an outside source
so there is a reverse chemical action. The lead-acid
chemicals store the electric energy until the electric
energy is needed to operate an electric device.
Figure 1. Lead-Acid Industrial Battery 1. VENT AND FILL 5. POSITIVE PLATE

CAP 6. EXPANSION MATS
A lead-acid battery is made from several lead-acid 2. POST 7. RETAINER
batteries called cells. Each cell has positive and 3. POST SEAL 8. SEPARATOR
negative plates with dielectric spacers between each 4. PLATE 9. NEGATIVE PLATE
plate. All of the plates are within a solution of PROTECTOR 10. BATTERY JAR
(SHIELD)
electrolyte. See Figure 2.
Figure 2. Battery Cell
1
Chemical Reaction in a Cell 2240 SRM 1
Specific Gravity
The strength of the electrolyte is measured in points of specific gravity. For example, a solution of sulfuric
acid has a specific gravity of 1.835. Water has a specific gravity of 1.000. Electrolyte is 27 percent acid and 73
percent water and has a specific gravity of 1.275.
Chemical Reaction in a Cell

During the discharge of the cell, lead peroxide and
WARNING sponge lead mix with sulfuric acid to make lead sul-
NEVER pour water into concentrated acid. fate (PbSO 4) on both plates. See Figure 4. This ac-
The quick generation of heat can cause the tion decreases the voltage in the cell. When the sul-
acid to boil and splash out of the container. furic acid is removed from the electrolyte, the specific
ALWAYS pour concentrated acid into water gravity of the electrolyte decreases. See Figure 5.
when making a dilute solution of acid. The potential difference of a discharged cell is ap-
proximately 1.75 volts.
In a fully charged cell, the electrolyte has a specific
gravity of 1.270 to 1.130. NEVER discharge a battery When a direct current is applied to a discharged cell,
below a specific gravity of 1.130. The battery can the lead sulfate is changed into lead and sulfuric acid.
have permanent damage if discharged below 1.130. The lead goes to the positive plate and stays as lead
and to the negative plate and stays as lead peroxide.
The cell generates a voltage (potential difference)
See Figure 6. The concentration of sulfuric acid in
when two different types of metal are in the elec-
the electrolyte increases. The specific gravity of the
trolyte. The two metals in a lead-acid cell are lead
electrolyte increases as the concentration of sulfuric
peroxide (PbO 3) for positive plates, and sponge lead
acid increases. In a fully charged cell, the positive
(Pb) for negative plates. See Figure 3. A poten-
plate again contains the lead peroxide and the nega-
tial difference of approximately 2 volts per cell is
tive plate contains the sponge lead.
generated. The potential difference does not vary
according to the size of the cell.
Figure 4. Discharging Cell

Figure 3. Fully Charged Cell
2
2240 SRM 1 Electrical Terms
Figure 5. Discharged Cell Figure 6. Charging Cell
Electrical Terms
Voltage is an electromotive force (EMF) (also called by the number of amperes. A kilowatt-hour is 1000
"potential difference") caused by the difference in watts of electric power used in 1 hour.
electric charge between two points. See Figure 7.
Ohms is the measurement of electrical resistance.
Ampere is a measurement of electric current.
Polarity. In a battery, the electric current is shown
Watt is a measure of electric power. The number to flow from the positive terminal to the negative ter-
of watts is equal to the number of volts multiplied minal.
Figure 7. Electrical Terms
3
Battery Selection 2240 SRM 1
Direct Current (DC). When the voltage between positive and negative at a quick and constant rate,
the two terminals is always the same polarity, the the voltage is called Alternating Current.
current flow and voltage are called Direct Current.
Alternating Current (AC). When the polarity of

voltage between two terminals is changing between
Battery Selection
The battery needed to operate a period of 8 hours de- Lift trucks are available in various voltage ranges.
pends on many conditions. Operations that require See Figure 8. The small "walkie" lift trucks are nor-
the lift truck to go up ramps or require the use of ad- mally 12 or 24 volts. The larger sit-down rider lift
ditional attachments increase the use of power from trucks are normally 24, 36, 48, 72, or 80 volts. The
the battery. Some work conditions require that more number of cells in a lead-acid battery gives the bat-
than one battery must be used during a work period. tery voltage. See Figure 9. A fully charged cell has
The number of 8-hour work periods per day is nor- a potential difference of approximately 2 volts. See
mally equal to the number of batteries needed. For Figure 8. This potential difference does not change
example, for three work periods, you need three bat- with size of the cell.
teries. The capacity of the battery you need is found
as follows:
• The size of the lift truck and the attachments.
• The type of work. Heavy-duty operation or normal
operation for one 8-hour work period.
Figure 9. Multicell Battery for Electric Lift

Truck
Figure 8. Cell Voltage
4
2240 SRM 1 Battery Ratings
Battery Voltage
The battery voltage you need is found as follows: To reach the necessary battery voltage, the cells are
• Will your lift truck operate on more than one volt- connected in series. For example:
age? 24 volts = 12-cell battery
• If you have more than one lift truck in operation, 36 volts = 18-cell battery
do the battery voltages need to be the same? 48 volts = 24-cell battery
72 volts = 36-cell battery
80 volts = 40-cell battery
Battery as a Counterweight
On electric lift trucks that use the battery as part of the lift truck is reduced. If the battery used in the
of the counterweight, the battery is part of the ca- lift truck is less than the size of the battery compart-
pacity of the lift truck to lift loads. The minimum ment, blocks and spacers must be installed to hold
weight of the battery is shown on the nameplate. If the battery in position.
the battery is not the minimum weight, the capacity
Battery Ratings
The ratings of batteries are measured in ampere- KILOWATT-HOURS
hours and kilowatt-hours at a constant rate of dis-
charge. A rating of 6 hours is the standard. Ampere- A kilowatt is 1000 watts. A watt is a measure of
hours is the measurement of battery capacity. To electric power. The capacity in kilowatt-hours is the
calculate ampere-hours, multiply amperes by hours. total power generated by the battery. Watt-hours
See Table 1. For example, 5 amperes times 5 hours are measured by multiplying the voltage by ampere-
is 25 ampere-hours. You cannot change the potential hours. To measure the kilowatt-hours, divide the
difference of a cell. You can increase the ampere-hour watt-hours by 1000.
rating by increasing the number of plates in a cell,
volts × amperes × hours
or by installation of larger plates. The constant rate = kilowatt-hours or kWh
of discharging can be compared to a measurement of 1000
the battery capacity and ampere-hours. For exam-
ple, a battery with a rating of 600 ampere-hours dur- To calculate the kilowatt-hours for a battery that has
ing a work period of 6 hours will generate 100 am- a rating of 600 ampere-hours and a 48-volt system,
peres per hour for 6 hours. The same battery cannot use this formula:
generate 300 amperes for 2 hours. The heat gener-
ated within the battery will damage the battery. 48 volts × 600 amperes × hours
= 28.8 kWh
Table 1. Battery Capacity Terms 1000
Amperes × Hours = Ampere-Hours The watt-hours can be converted to kilowatt-hours

to indicate the battery needed for the operation. Al-
600 Ampere Hours = 100 Amperes for 6 Hours ways select the correct type of battery. Remember,
Volts × Amperes × Hours/1000 = Kilowatt-Hours a battery that has a rating of 300 ampere-hours will
(KWH) not do the same job as a battery that has a rating of
600 ampere-hours. Do not permit the specific gravity
to go below the limits shown in the manual.
5
Battery Maintenance 2240 SRM 1
Battery Maintenance
Battery maintenance must include the following 8. If electrolyte is spilled on a work surface or the
items: floor, flush area with water, use a solution of soda
• A good battery charger (sodium bicarbonate) to make the acid neutral.
• A clean battery
• Keep the electrolyte at the correct level 9. Only trained persons are permitted to do main-
• Keep a record of the battery tenance on batteries and battery chargers. Make
sure the regulations by government safety agen-
SAFETY PROCEDURES cies, government insurers, private insurers, and
private organizations are followed when doing
1. Wear a rubber apron, gloves, boots, and goggles maintenance on batteries.
or a face shield when doing maintenance on bat-
teries. MAINTENANCE RECORDS
2. Batteries generate hydrogen gas when they are NOTE: Follow the same sequence when you record
being charged. Keeps open fire away from bat- the cell number. Always begin the record with a pos-
teries. Do not check the electrolyte level with a itive cell. Follow a sequence so the last cell is always
match or a lighter. Do not smoke and do not cre- the cell for the negative cable.
ate sparks.
Record the beginning ampere reading of the charger
3. Lift batteries correctly with a crane or equipment each time the battery is charged. Any difference in
designed for the job. Always use a spreader bar the daily ampere reading can indicate a problem with
designed and adjusted for the battery. Move bat- the battery or the charger.
teries with a lift truck or a conveyor or rollers de-
signed for that purpose. If the battery does not NEW BATTERY
have a cover, a rubber mat or insulating material
must be put over the top of the battery to prevent CAUTION
a short circuit with other equipment. Make sure
Always use a spreader bar and slings that lift
the lifting equipment has enough capacity for the
vertically on the lifting eyes of the battery. DO
job. Do not use chain or wire rope slings.
NOT use a chain or sling without a spreader
4. Never put metal materials or tools on a battery. bar or you will damage the battery case.
5. Disconnect battery from lift truck before doing Use the correct blocks or spacers to hold the
maintenance or repairs. battery in position in the lift truck. Make sure
the battery compartment is clean and dry. All
6. When maintenance on the battery or the battery vent caps must be in position when the battery
charger is required, disconnect both the AC and is in service. If the vent caps are not installed,
DC power. If the battery connectors must be re- the electrolyte will leak, causing corrosion on
placed, make sure the positive and negative ter- the battery case and in the battery compart-
minals and cables are kept separate and insu- ment.
lated from each other. Even a momentary short
circuit can cause an explosion and damage the Inspect a new battery for damage. Make sure the
battery. electrolyte in each of the cells is at the correct level.
Charge the battery for 6 hours or until the specific
7. Keep water readily available to flush spilled elec- gravity is correct. Make sure the battery is correctly
trolyte. Electrolyte in the eyes must be flushed installed in the lift truck. Use a spreader bar with
with water immediately, and then quickly get slings designed for the battery to lift and move the
medical attention. Special showers and eye battery. See Figure 10.
wash systems are required in areas where bat-
tery maintenance is done. Always complete the Battery Inspection Report and
the Daily Battery Report. See Figure 11 and Fig-
ure 12.
6
2240 SRM 1 Battery Maintenance
CLEANING BATTERY
Keep the battery compartment clean and dry. Use a
clean cloth to wash the battery with water. Dry with
compressed air.
CAUTION
Do not clean the battery with steam or hot wa-
ter. Do not use a high-pressure hose.
Remove any electrolyte from the battery compart-

ment to prevent corrosion. If there is electrolyte on
the top of the battery, apply a solution of bicarbonate
of soda. Mix a solution containing 0.5 kg of soda for
every 4 liters of water. Apply the solution, then flush
the solution from the battery with clean water. Wash
the battery and battery compartment as needed, but
within a 6 month period as the maximum time.
NOTE: If the top of the battery is wet from elec-

trolyte, check that the electrolyte level is not too high
or the battery charger is not operating correctly.
1. INSULATED 2. INSULATED
SPREADER BAR STRAPS
Figure 10. Change the Battery
Figure 11. Battery Inspection Report
7
Figure 12. Daily Battery Report
ADDING WATER TO BATTERY vent plugs. The electrolyte can flow out of the cell
through the fill hole. The correct electrolyte level is
NOTE: Some batteries have sealed cells. These bat- shown in Figure 13.
teries do not need water added to the electrolyte.
Some water is lost from the electrolyte of each cell

during the charge and discharge cycle when the bat-
tery is in service. Check the electrolyte level daily.
Some service persons check some of the cells each day
so all cells are checked each week. If the level of the
electrolyte goes below the level of the top of the sep-
arators for the plates, the cell can be damaged.
KEEPING THE ELECTROLYTE LEVEL WITHIN

THE CORRECT LIMITS IS THE MOST IMPOR-
TANT ITEM OF BATTERY MAINTENANCE.
See the instructions from the manufacturer of your

battery for the operating level of the electrolyte. Al- 1. FILL TUBE 5. MINIMUM LEVEL
ways use distilled water. If you add distilled water, 2. BOTTOM OF FILL OF ELECTROLYTE
wait 5 minutes before measuring the specific grav- TUBE 6. PLATE
3. CELL COVER PROTECTOR
ity with a hydrometer. DO NOT add water to a cell 4. MAXIMUM LEVEL 7. TOP OF
before or during the charging cycle; water must be OF ELECTROLYTE SEPARATORS
added after the charging cycle. If water is added be-
fore the charging cycle, the electrolyte level may rise, Figure 13. Electrolyte Level
which will cause electrolyte to be forced out of the
8
HYDROMETER electrolyte level is low, the percent of sulfuric acid in

the electrolyte increases. When the electrolyte level
NOTE: Some batteries have sealed cells. The specific decreases by 3 mm (1/8 in.), the specific gravity mea-
gravity of the electrolyte cannot be checked on these surement can increase by 3 to 5 points.
batteries.
When you use the hydrometer, make sure there is
Use a hydrometer to measure the specific gravity of enough liquid in the barrel to let the float move freely.
the battery. Make sure there is enough electrolyte in The float must not touch the side, top, or bottom of
the battery cells. See Adding Water to Battery in this the barrel. See Figure 14 for the correct method of
section. A high level or low level of the electrolyte can reading the hydrometer.
change the specific gravity measurement. When the
1. HIGH FLOAT MEANS HIGH SPECIFIC GRAVITY.

2. LOW FLOAT MEANS LOW SPECIFIC GRAVITY.
3. CORRECT METHOD OF READING HYDROMETER: EYE LEVEL EVEN WITH SURFACE OF
ELECTROLYTE.
Figure 14. Reading Hydrometer
BATTERY TEMPERATURE is increased and make sure the charge or discharge

rate is not too high. A recommendation for a battery
The temperature of the electrolyte will change the in service is 8 hours of use (discharge), followed by 8
reading of the specific gravity. When the tempera- hours of cooling, followed by 8 hours of charging.
ture increases approximately 6 C (10 F), the specific
gravity will decrease by 0.003 point. See Figure 15 To charge the battery, a direct current must pass
for making specific gravity corrections. If the hy- through the cells in the opposite direction to the dis-
drometer you are using does not have a temperature charging current. The ampere-hours must be equal
correction, you will have to use a thermometer. Spe- to the discharging ampere-hours plus the energy lost
cial battery thermometers are available that will in- as heat. This additional amount of charge will vary
dicate the correction factor directly and add or sub- according to the battery and the temperature, but the
tract the correct number of points. See Figure 16. average additional charge is 12 percent. When the
battery is nearly charged, the final charging must be
NEVER charge a battery at a rate that will raise the at a low rate. A charging rate that is too high will
electrolyte temperature above 49 C (120 F). NEVER cause heating in the battery and a high loss of wa-
let a battery stay discharged for long periods. A tem- ter from the electrolyte. The charging of the battery
perature above this amount will damage the battery. must be done correctly, or the service life of the bat-
The cells in the center of the battery are normally at tery will be decreased.
the highest temperature. If the battery temperature
is too hot, make sure the ventilation of the battery
9
has sealed cells. The sealed batteries require a dif-

ferent charger. The electrolyte level or specific grav-
ity cannot be checked, and water cannot be added to
the electrolyte of these sealed batteries.
WARNING
The acid in the electrolyte can cause injury.
If electrolyte is spilled, use water to flush the
area. Make the acid neutral with a solution of
sodium bicarbonate.
Batteries generate explosive fumes when they

are being charged. Keep fire, sparks, and burn-
ing material away from the battery charger
area. Prevent sparks from the battery connec-
tors.
Charge batteries only in the special area for

Specific Electrolyte Correction Correct
charging batteries. When charging the bat-
Gravity Temp. Points Value
teries, keep the vent caps clean. The battery
Reading
charger area must have ventilation so that
1.210 31 C (88 F) +0.003 1.213 explosive fumes are removed. Open the hood
over the battery or remove the cover if the
1.210 27 C (81 F) +0.001 1.211
battery has a cover.
1.210 25 C (77 F) 0.000 1.210
Disconnect the battery when doing cleaning
1.210 18 C (64 F) 0.004 1.206 and maintenance.
+0.001 or 0.001 for each 2 degrees C from the
If the lift truck has been operated with a low
25-degree base value.
battery, check the contactors for welded con-
tacts before a charged battery is connected.
Figure 15. Specific Gravity Check The circuit will not reset and lift truck oper-
ation cannot be controlled if the contacts are
welded. To check the contacts, see the section
EV-100 SCR Motor Controller 2200 SRM 557.
CAUTION
Use only battery chargers approved by the bat-
tery manufacturer or dealer.
CAUTION
NEVER connect the battery charger plug to
the plug of the lift truck. You can damage the
traction control circuit. Make sure the charger
voltage is the correct voltage for the battery.
Correct use of the hydrometer (see Figure 14) and

proper operation of the battery charger is impor-
Figure 16. Battery Thermometer tant. Also see Figure 15. Follow the instructions of
the charger manufacturer. NEVER let the battery
CHARGING BATTERY discharge below the minimum value given by the
battery manufacturer. A fully charged battery will
NOTE: There can be one of two types of batteries. have a specific gravity of 1.265 to 1.310 at 25 C
One type has removable cell caps. The other type
10
(77 F). See Figure 15. 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.
Types of Battery Charges

1. NORMAL CHARGE. This charge is usually
given to a battery that is discharged from nor-
mal operation. This is often an 8-hour charge.
Many customers charge the battery at regular
intervals that depend on use. This procedure will
keep the battery correctly charged if the battery
is not discharged below the limit. Always use a
hydrometer to check the battery if the battery is
charged at regular intervals. Frequent charging
of a battery that has a 2/3 or more charge can
decrease the life of the battery.
2. EQUALIZING CHARGE. This charge is at a low

rate and balances the charge in all the cells. The
equalizing charge is usually given approximately
once a month. It is a charge at a slow rate for 3
to 6 hours in addition to the regular charging cy-
cle. 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 dif-
ference is more than 0.020 between cells of the
battery after an equalizing charge, there can be
a damaged cell. Consult your battery dealer.
NOTE: Many customers have battery chargers that

can follow a program to automatically charge a
battery according to recommendations of the battery
manufacturer. Use the recommendations of the Figure 17. Specific Gravity Versus Percent
battery manufacturer for charging the battery. See Discharge
the section DC Motor Maintenance 620 SRM 294
for additional information.
The discharge limits and the limits for the specific

gravity before the battery must be charged again are
shown in Figure 17. NEVER discharge a battery be-
low the limits shown in Figure 18. Discharging a bat-
tery beyond the design limits will decrease the ser-
vice life of the battery.
NOTE: Sometimes the capacity of a battery is not

enough to complete a work period. Check for the fol-
lowing conditions:
• The battery is too small for the job. Figure 18. Specific Gravity Compared to
• The battery is not fully charged. Charging Time
• The battery charger is not operating correctly.
• The battery is near the end of its service life.
11
Methods of Charging a lower rate. Two resistors control the charging

rate. One resistor controls the charging rate at
There are three methods of charging a battery. the beginning of the cycle and a second resistor
reduces the charging rate when the voltage in the
1. GRADUAL CHARGE. This method uses a
cells reaches 2.37 volts. A relay automatically
solid-state automatic battery charger. The
controls the second resistor. The two-rate charg-
charging rate begins at 20 to 25 amps/100
ing cycle is shown in Figure 21.
amp-hours and decreases to less than 5 amps/100
amp-hours when the battery is 80 percent
charged. The charging current decreases when
the voltage across the cell increases during the
charging cycle shown in Figure 19. The increase
in the voltage from the charger is approximately
the same as the increase in the specific gravity
in the cells.
Figure 20. Modified Constant Voltage Charger
Figure 19. Specific Gravity Compared to

Charging Time
2. MODIFIED CONSTANT VOLTAGE. This

method uses a generator to generate a con-
stant voltage that is controlled by a resistor.
When the charging current decreases, the volt-
age across the resistor increases. The increasing
voltage across the resistor causes an increasing
voltage at the battery terminals. The charging
is similar to the gradual charge. The resistor Figure 21. Two-Rate Charging Cycle
must be correctly set, or the charging rate will
be wrong. The typical graphs for a modified NOTE: Many users have battery chargers that can
constant voltage charger are shown in Figure 20. follow a program to automatically charge a battery
according to recommendations of the battery man-
3. TWO-RATE CHARGE. This method also uses a ufacturer. Use the recommendations of the battery
high charging rate at the beginning followed by manufacturer for charging the battery.
12
Troubleshooting Charger either fully charged or in the final stage of charg-

ing.
Battery chargers normally operate automatically
without constant attention. It is necessary to make 3. The specific gravity reading is constant and
a periodic check that the charger is operating cor- within the limits of a charged battery. If the tem-
rectly. Check for the following conditions: perature increases after the battery is charged,
the specific gravity will decrease a small amount.
1. Battery temperature is too high. The temper-
ature in a battery will not normally rise more 4. Constant meter indications on the charger will
than 14 C (25 F) during an 8-hour charging pe- indicate the end of the charging cycle.
riod. Higher temperatures indicate the charging
rate needs adjustment. WHERE TO CHARGE BATTERIES
2. Continuous operation of the charger. Check the To increase the service life and reduce maintenance,
automatic controls on the charger. Check the a special area is needed for charging the batteries.
charging rate. A low charging rate can be the The following information is necessary for the design
problem. of this area:
• Location of power supply
3. Continuous operation of a charger at a high rate. • Ventilation; hydrogen gas comes from the batteries
Normally, the charging rate begins at a high rate during charging
and decreases as the battery becomes charged. • Drains for cleaning the batteries
If the rate does not decrease, the controls need • Type and size of the batteries
repair or adjustment. • Type of lift trucks
• Distances the lift trucks must travel for service
Knowing When Battery Is Fully Charged • Safety regulations and instructions
WARNING Equipment Needed

Always connect the positive cable to the pos- • A lifting device to remove the battery from the lift
itive terminal and connect the negative cable truck
to the negative terminal. Any other connection • Racks to hold the batteries during charging and
will cause injury and damage. storage (these racks must be made of wood or must
not be metal; metal racks that are covered with an
Always charge the battery at the end of the
insulating material can be used)
work period (shift). Never let the specific
• A battery charger that will charge your batteries
gravity decrease to a level less than the limits
• Tools for maintenance
shown in the manual.
• An area with a drain for cleaning batteries and bat-
Always de-energize the charger before you con- tery compartments
nect or disconnect the charger from the bat- • Distilled water
tery. • Air and water supplies for cleaning
• Maintenance records (see Figure 11 and Figure 12)
NEVER connect the battery charger plug to • A workbench
the plug of the lift truck. You can damage the • Spare parts and repair equipment
traction control circuit. Make sure the charger • Protective clothing and safety equipment for han-
voltage is the correct voltage for the battery. dling batteries
• Water source for washing eyes and preventing acid
1. During charging, the voltage increases slowly. burns
When the battery is fully charged, the voltage • Install a NO SMOKING sign in the service area
level is constant. • Keep the charger in a clean, dry area with good
ventilation
2. Remove a vent cap and look in the opening. If
you see bubbles in the electrolyte, the battery is
13
BATTERY CONNECTORS BATTERY CARE

A special heavy-duty connector is used to connect the 1. Keep batteries clean. Remove any spilled elec-
battery to the electrical system of the lift truck. See trolyte.
Figure 22 and Figure 23. When a connector has a
handle and is within the operator’s reach, the connec- 2. DO NOT overcharge the battery. This action will
tor is also a safety device that can be used to quickly damage the battery.
disconnect the battery in an emergency. Most con-
3. DO NOT discharge the battery to less than the
nectors have a handle to connect the two halves of the
recommendation. A deep discharge will shorten
connector. The connector can be quickly disconnected
the battery life.
by pulling the handle upward. This action separates
the two halves of the connector. The connector and 4. Charge batteries in an area with good ventilation
its attached handle must be kept in good repair so to remove explosive gases and acid fumes.
that it will function correctly. The battery connec-
tor must be disconnected when maintenance is done 5. Keep the electrolyte at the correct level. Check
on the lift truck that does not require electric power. the electrolyte level before and after charging the
The SBE, SBX, and FEM or DIN 12- volt battery con- battery. Use distilled water. Do not add acid.
nectors are shown in Figure 23.
6. Prevent batteries from freezing.
7. Keep batteries charged. A discharged battery in

storage will shorten the battery life.
8. Use a battery charger that is correct for the bat-

tery. A battery charger that is set for an am-
pere-hour rate that is too high will cause a high
internal heat and damage the battery. A low am-
pere-hour rate setting on a battery charger can
require a longer charging time but will not dam-
age the battery.
9. When batteries are moved, make sure a short

circuit does not occur. See the Safety Procedures
in Battery Maintenance of this section.
1. SB CONNECTOR FOR BATTERY CABLES

2. SB CONNECTOR FOR POWER CABLES TO
LIFT TRUCK
3. BRACKET
4. CONNECT AND DISCONNECT HANDLES
Figure 22. SB Battery Connector
14
NOTE: INDICATOR INSERT (2). GREEN - FOR BATTERY WITH CELL CAPS. GRAY - FOR BATTERY WITH
SEALED CELLS.
NOTE: CONNECTOR BODY COLOR [ANDERSON SBE CONNECTOR ONLY (1)]. GRAY - 36-VOLT BATTERY.
BLUE - 48-VOLT BATTERY. GREEN - 72-VOLT BATTERY. BLACK - 80-VOLT BATTERY.
A. ANDERSON SBE OR SBX CONNECTOR B. FEM OR DIN CONNECTOR
1. HALF OF CONNECTOR SET 9. +12 VOLT WIRE TO TRUCK (TRUCK HALF) OR
2. RED HOUSING FOR +12 VOLT "BATTERY TAP" TO BATTERY (BATTERY HALF)
3. LOCK SPRING (TIP OF CONTACT MUST LOCK 10. INDICATOR INSERT FOR BATTERY VOLTAGE
OVER TOP OF LOCK SPRING) AND BATTERY TYPE [ROTATE FOR CORRECT
4. BLACK CONNECTOR HOUSING (ASSEMBLED VOLTAGE IN WINDOW (12); COLOR SHOWS
ON RED HOUSING WITH SLOTS FOR LOCK BATTERY TYPE]
PINS ALIGNED AS SHOWN - NO WIRE OR 11. LOCK FOR ALL CABLE TERMINALS AND
CONTACT IN HOUSING) INDICATOR
5. SLOT FOR LOCK PIN 12. WINDOW SHOWING BATTERY VOLTAGE
6. CONTACT FOR CONNECTOR OF +12 VOLT 13. IN-LINE FUSE ASSEMBLY AND CONTACT
BATTERY TAP FOR +12 VOLT CONNECTOR (TRUCK HALF
7. KEY [RED (2) AND BLACK (4) CONNECTORS OF BATTERY CONNECTOR ONLY) (SBE/SBX
ALIGN ON KEY] CONTACT SHOWN)
8. LOCK PINS FOR +12 VOLT CONNECTOR (MUST
INSTALL FROM FRONT OF CONNECTOR
THROUGH RED AND BLACK CONNECTORS)
Figure 23. Detail of Battery Connectors With +12 Volt Tap
15
NOTES
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16
2240 SRM 1 11/03 (3/03)(2/02)(3/00)(9/96)(5/96)(2/94)(1/83)(7/78) Printed in United Kingdom

MAST
DESCRIPTION
H/S/E1.50-1.75XM (H/S/E25-35XM) [C010, D001, D010, D114, E001];
H/S/E2.00XMS (H/S/E40XMS) [C010, D001, D010, D114, E001];
H/S/E/2.00-3.20XM (H/S/E/40-65XM) [D177, D187, F108];
J2.00-3.20XM (J40-60XM, J40-60XM 2) [A216];
J2.00-3.20XM (J40-65Z) [A416];
S/E/J2.00-3.00XL With Mast S/N C507-509 and C562-564
(S/E/J40-60XL) [A187, B168, B187, C108, C187];
J1.60-2.00XMT (J30-40XMT) [C160, F160];
H2.00-3.20XM (H45-65XM) [H177];
J30-40XMT 2 [H160];
E1.50-2.00XM (E25-35Z, E40ZS) [E114];
E2.00-3.20XM (E45-65Z) [G108];
J1.60-2.00XMT (J30-40ZT) [J160]
PART NO. 897506 4000 SRM 521

SAFETY PRECAUTIONS

trucks.
nance section.
manual:
WARNING
CAUTION
Mast Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Description and Operation ................................................................................................................................ 1
Carriages ........................................................................................................................................................ 1
Mast Mounts .................................................................................................................................................. 3
Two-Stage Mast, Limited Free-Lift (LFL) ........................................................................................................ 5
Description and Operation ............................................................................................................................ 5
Two-Stage Mast, Full Free-Lift (FFL) .............................................................................................................. 6
Three-Stage Mast, Full Free-Lift (FFL) ........................................................................................................... 8
Cylinder Cushion During Lifting Sequence ..................................................................................................... 11
Cylinder Cushion During Lowering Sequence ................................................................................................. 12
H/S/E1.50-1.75XM (H/S/E25-35XM) [C010, D001, D010, D114, E001];

H/S/E2.00XMS (H/S/E40XMS) [C010, D001, D010, D114, E001];
H/S/E/2.00-3.20XM (H/S/E/40-65XM) [D177, D187, F108];
J2.00-3.20XM (J40-60XM, J40-60XM 2) [A216];
J2.00-3.20XM (J40-65Z) [A416];
S/E/J2.00-3.00XL With Mast S/N C507-509 and C562-564 (S/E/J40-60XL)
[A187, B168, B187, C108, C187];
J1.60-2.00XMT (J30-40XMT) [C160, F160];
H2.00-3.20XM (H45-65XM) [H177];
J30-40XMT 2 [H160];
E1.50-2.00XM (E25-35Z, E40ZS) [E114];
E2.00-3.20XM (E45-65Z) [G108];
J1.60-2.00XMT (J30-40ZT) [J160]

"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
4000 SRM 521 Description and Operation
General
This section has the description and operation of the tilt cylinders are fastened between the frame of the
masts. Repair procedures for the masts are described lift truck and the outer mast weldment. Hydraulic
in the section Mast, Repairs 4000 SRM 522. The lift cylinders are installed vertically on the masts.
description and repairs for the tilt cylinders are de- The lift cylinders raise and lower the mast weld-
scribed in the section Tilt Cylinders 2100 SRM 103. ments and the carriage.
The mast is used to lift a load vertically. The mast There are three types of masts available:
has two movements controlled by hydraulic cylin- • Two-stage, Limited Free-Lift
ders: forward and backward tilt, and the lifting and • Two-stage, Full Free-Lift
lowering of the mast weldments and carriage. The • Three-stage, Full Free-Lift
outer weldment can move on the pivot pins at the
mast mounts. The operation of the tilt cylinders Each type of mast is described separately in this sec-
causes the mast to tilt forward and backward. The tion.
Description and Operation

CARRIAGES other types of load handling equipment are attached
to the carriage. A load backrest extension is attached
The carriage is a part of the mast assembly. Load to the carriage and adds support for a load that has
rollers that are attached to the carriage travel in the multiple pieces. See Figure 1.
inner channels of the inner mast weldment. Forks or
A. HANG-ON SIDESHIFT CARRIAGE B. STANDARD CARRIAGE WITH FORKS

1. STANDARD CARRIAGE 6. SIDESHIFT CYLINDER
2. TOP BAR 7. BOTTOM BAR
3. TOP BEARING 8. FORKS
4. CYLINDER MOUNTING BRACKET 9. LOAD BACKREST EXTENSION
5. BOTTOM BEARING
Figure 1. Carriages
1
Description and Operation 4000 SRM 521
The hang-on sideshift carriage lets the operator The integral sideshift carriage lets the operator move
move the forks and load from side to side. This the forks and load from side to side. This function
function makes it easier for the operator to align the makes it easier for the operator to align the forks
forks with a load or align the load with a stack. The with a load or align the load with a stack. The in-
hang-on sideshift carriage hangs on the fork bars of tegral sideshift carriage is a complete carriage and
the standard carriage. Special bushings fit between sideshift assembly. The sideshift cylinder moves the
the hang-on sideshift carriage and the fork bars. A sideshift carriage on the standard carriage. See Fig-
sideshift cylinder is installed on a plate that fits on ure 2.
the standard carriage. The sideshift cylinder moves
the hang-on sideshift carriage on the standard car-
riage.
Figure 2. Integral Sideshift Carriage
2
4000 SRM 521 Description and Operation
Legend for Figure 2

1. INNER CARRIAGE 9. CLEVIS PIN 17. COTTER PIN
2. OUTER CARRIAGE 10. HAIRPIN 18. LOAD ROLLER
3. SIDESHIFT CYLINDER 11. PIN 19. SHIMS
4. UPPER BEARING 12. LUBE FITTING 20. SPACER
5. LOWER BEARING 13. PIN 21. SNAP RING
6. LOWER HOOK 14. CHAIN ANCHOR 22. SPACER
7. CAPSCREW 15. SNAP RING
8. WASHER 16. PIN
MAST MOUNTS E40XMS) (D114), E1.50-2.00XM (E25-35Z, E40ZS)

(E114), and J1.60-2.00XMT (J30-45XMT) trucks, the
The mast can tilt forward and backward. Tilt cylin- mast pivots directly on the drive axle housing. The
ders are fastened between the frame of the lift truck mounts are part of a casting that includes the lower
and the outer mast weldment to change the angle of crossmember for the outer channel. Each mount
the mast and forks. has a retainer cap that attaches the mast to the
axle housing. Each mast mount uses one bushing.
On the S/E/J2.00-3.00XL (S/E/J40-60XL), the mast
There are no bushings used in the retainer caps. See
pivots directly on the drive axle housing. The mounts
Figure 4.
are part of a casting that includes the lower cross-
member for the outer channel. Each mount has a re-
tainer cap that attaches the mast to the axle housing.
Each mast mount uses two bushings. See Figure 3.
1. RETAINER CAP 5. BUSHING

2. SPACER 6. SHIMS
3. TILT CYLINDER 7. PIN 1. RETAINER CAP 6. SHIMS
4. OUTER MAST 8. ROD END 2. SPACER 7. PIN
WELDMENT 3. TILT CYLINDER 8. ROD END
4. OUTER MAST 9. O-RING
Figure 3. Mast Mounts WELDMENT 10. CAPSCREW
5. BUSHING 11. FLAT WASHER
On H1.50-1.75XM, H2.00XMS (H/S25-35XM,
H/S40XMS), E1.50-1.75XM, E2.00XMS (E25-35XM, Figure 4. Mast Mounts
3
Description and Operation 4000 SRM 521
On the H/S/2.00-3.20XM (H/S/40-65XM), E2.00- On J30-40ZT trucks, the mast pivots on two stub-
3.20XM (E40-65XM) (F108), E2.00-3.20XM (E45- shafts welded to the sides of the outer mast weld-
65Z) (G108), J2.00-3.20XM (J40-60XM, J40-60XM 2) ment. The mast mounts are part of the transmission
(A216), and J2.00-3.20XM (J40-65Z) (A416) trucks, housing, which bolt to the truck frame. Each mount
pivot pins are installed in the drive axle hangers. uses one bushing. Each mount has a retainer cap
The outer mast weldment has mounts that fit on that attaches the mast to the mast mount. Each re-
the pivot pins. Capscrews hold the mast to the pivot tainer is held in place with four capscrews. See Fig-
pins. See Figure 5. ure 6.
1. RETAINER CAP 6. NUT

2. LOCKWASHER 7. PIN
1. SPACER 7. O-RING 3. TILT CYLINDER 8. ROD END
2. TILT CYLINDER 8. PIVOT PIN 4. OUTER MAST 9. WASHER
3. OUTER MAST 9. DRIVE AXLE WELDMENT 10. CAPSCREW
WELDMENT HANGER (MAST 5. BUSHING
4. SHIMS MOUNT)
5. PIN 10. COTTER PIN Figure 6. Mast Mounts
6. ROD END
Figure 5. Mast Mounts
4
4000 SRM 521 Two-Stage Mast, Limited Free-Lift (LFL)
Two-Stage Mast, Limited Free-Lift (LFL)

DESCRIPTION AND OPERATION Legend for Figure 7
NOTE: TYPICAL MAST ASSEMBLY IS SHOWN

HERE.
1. OUTER 4. LIFT CYLINDER(S)
WELDMENT 5. LOWERING
2. INNER WELDMENT CONTROL VALVE
3. LIFT CHAIN(S) (EXTERNAL)
The two-stage mast with limited free-lift has an outer

weldment, an inner weldment, and two lift cylinders.
See Figure 7. At the base of the inner weldment there
is one load roller on each side. These load rollers
travel along the flanges inside the outer weldment.
At the top of the outer weldment there is also one load
roller on each side. These load rollers travel along
the flanges on the outside of the inner weldment. The
angle of the load rollers permits them to control the
forces from the front, back, and sides of the mast.
The strip bearings are installed at the top of each
outer channel. The strip bearings can be adjusted
by shims to help keep the correct clearance between
the outer weldment and the inner weldment.
The two single-stage lift cylinders are installed at the

back of the outer weldment. The base of each lift
cylinder sits in a mount at the bottom crossmember
on the outer weldment. The top of each lift cylinder
(cylinder rods) fits into a guide at the top of the in-
ner weldment. Operation of the lift cylinders extends
and retracts the inner weldment. See Figure 8.
Two lift chains move the carriage. The chains fasten

to mounts that are near the top of the lift cylinder
shells. The chains go up and over the chain sheaves
and connect to the carriage. The chain sheaves are
installed at the top crossmember of the inner weld-
ment. When the lift cylinders extend, the lift chains
transfer the force from the lift cylinders to the car-
riage. The inner weldment and carriage can raise a
small amount before the overall height of the mast
increases. During lifting, the inner weldment moves
at the same speed as the lift cylinders. The carriage
moves at twice the speed of the inner weldment.
When the lift cylinders retract, the weight of the load,

carriage, and inner weldment pushes the oil from the
lift cylinders. The oil flows from the lowering control
valves in the lift cylinders, through the external low-
ering control valve to the hydraulic tank.
Figure 7. Two-Stage Mast, Limited Free-Lift
(LFL)
5
Two-Stage Mast, Full Free-Lift (FFL) 4000 SRM 521
Each cylinder has a check valve in the bottom of the This action allows the cylinder to fully extend. See
rod assembly. When the cylinder is fully extended, oil Cylinder Cushion During Lowering Sequence.
above the piston is forced through the check valve.
1. LIFT CYLINDER 5. OUTER WELDMENT

2. LOWERING CONTROL VALVE (INTERNAL) 6. INNER WELDMENT
3. LOWERING CONTROL VALVE (EXTERNAL) 7. LIFT CHAIN
4. TO/FROM MAIN CONTROL VALVE 8. CARRIAGE
Figure 8. Operation of Two-Stage Mast, Limited Free-Lift (LFL)
Two-Stage Mast, Full Free-Lift (FFL)

DESCRIPTION AND OPERATION outer weldment. The top of each lift cylinder (cylin-
der rod) fits into a guide at the top of the inner weld-
The two-stage, full free-lift mast has an inner weldment. The free-lift cylinder is installed in the inner
ment and an outer weldment. See Figure 9. It is weldment. Each of the lift cylinders has an inter-
called a full free-lift mast because the carriage can nal lowering control valve. A single external lower-
travel to the top of the inner weldment without ex- ing control valve is connected by tubing to all the lift
tending the inner weldment. The full free-lift mast cylinders.
has the same load roller and strip bearing arrange-
ments as the two-stage, limited free-lift mast. The free-lift chains connect at one end to the cross-
member for the free-lift cylinder. Two chain sheaves
The two main lift cylinders are installed at the back are installed on a crosshead on the cylinder rod of the
of the outer weldment. The base of each lift cylinder free-lift cylinder. The chains go over sheaves on the
sits in a mount at the bottom crossmember on the crosshead and connect to the carriage.
6
4000 SRM 521 Two-Stage Mast, Full Free-Lift (FFL)
Legend for Figure 9
NOTE: TYPICAL MAST ASSEMBLY IS SHOWN

HERE.
1. OUTER WELDMENT
2. INNER WELDMENT
3. FREE-LIFT CHAIN
4. FREE-LIFT CYLINDER
5. MAIN LIFT CYLINDER(S)
6. LOWERING CONTROL VALVE (EXTERNAL)
The three lift cylinders are connected by hoses and

tubing as shown in Figure 10. When the mast is ex-
tended, oil flows from the main control valve to the
base of the main lift cylinders. The oil flows through
the left-hand cylinder rod and through tubing to the
base of the free-lift cylinder. The free-lift cylinder
raises only the carriage. When the free-lift cylinder
is fully extended, the two main lift cylinders extend
the inner weldment. The free-lift cylinder extends
first because it has less weight to lift. When the load
is lowered, the main lift cylinders lower first because
they have a greater load. The oil flows from the main
lift cylinders, through the lowering control valve to
the hydraulic tank. Oil from the free-lift cylinder
flows from the cylinder through tubing to the cylin-
der rod on the left side of the mast. The oil flows from
the left-hand lift cylinder to the hydraulic tank.
The free-lift cylinder must have 0.5 liter (0.5 qt) of oil
above the piston. This oil provides a hydraulic cush-
ion when the cylinder reaches the top of its stroke. A
check valve and orifice system in the bottom of the
rod assembly keeps the oil at the correct level. When
the cylinder is fully extended, excess oil above the
piston is forced through the check valve. This action
allows the cylinder to fully extend.
The right hand main lift cylinder has an orifice sys-

tem in the bottom of the rod assembly. This sys-
tem provides a hydraulic cushion when the cylinder
reaches the bottom of its stroke. See Cylinder Cush-
ion During Lifting Sequence.
Figure 9. Two-Stage Full Free-Lift Mast
7
Three-Stage Mast, Full Free-Lift (FFL) 4000 SRM 521
1. RIGHT-HAND LIFT CYLINDER 6. TO/FROM MAIN CONTROL VALVE

2. LEFT-HAND LIFT CYLINDER 7. OUTER WELDMENT
3. FREE-LIFT CYLINDER 8. INNER WELDMENT
4. LOWERING CONTROL VALVE (INTERNAL) 9. LIFT CHAIN
5. LOWERING CONTROL VALVE (EXTERNAL) 10. CARRIAGE
Figure 10. Operation of Two-Stage Mast, Full Free-Lift (FFL)
Three-Stage Mast, Full Free-Lift (FFL)

DESCRIPTION AND OPERATION main lift cylinders are installed at the back of the
outer weldment. The base of each lift cylinder sits
The three-stage mast has three weldments: outer, in a mount at the bottom crossmember of the outer
intermediate, and inner. See Figure 11. Two sin- weldment. The top of each main lift cylinder (cylin-
gle-stage main lift cylinders and a free-lift cylinder der rod) fits into a guide at the top crossmember of
are used to raise the carriage and extend the mast. the intermediate weldment. The free-lift cylinder is
It is called a full free-lift mast because the carriage installed to the inner weldment. Each lift cylinder
can travel to the top of the inner weldment without has an internal lowering control valve. A single ex-
extending the inner weldment. The weldments are ternal lowering control valve is connected by tubing
telescopic and have the load roller and strip bearing to all of the lift cylinders.
arrangements similar to the two-stage mast. The two
8
4000 SRM 521 Three-Stage Mast, Full Free-Lift (FFL)
The two main lift chains are connected to mounts

that are welded near the top of the lift cylinder shells.
The lift chains go over sheaves at the top of the in-
termediate weldment and fasten at the bottom of the
inner weldment.
The free-lift chains connect at one end to the cross-

member for the free-lift cylinder. Two chain sheaves
are installed on a crosshead on the cylinder rod of the
free-lift cylinder. The chains go over sheaves on the
crosshead and connect to the carriage.
The three hydraulic cylinders are connected by hoses

and tubing as shown in Figure 12. To extend the
mast, oil from the main control valve flows to all
cylinders at the same time. The free-lift cylinder ex-
tends first because it lifts the least amount of weight.
The free-lift cylinder raises the carriage to the top
of the inner weldment. After the free-lift cylinder
reaches the end of its stroke, the main lift cylinders
begin to extend. As the main lift cylinders extend,
the intermediate weldment is raised by the lift cylin-
ders and the inner weldment is raised by the lift
chains.
During lowering, the main lift cylinders lower first

because they have a greater load. After the main lift
cylinders have retracted, the free-lift cylinder lowers.
All oil from the lift cylinders flows through the low-
ering control valves to the hydraulic tank.
The free-lift cylinder must have 0.5 liter (0.5 qt) of oil
above the piston. This oil provides a hydraulic cush-
ion when the cylinder reaches the top of its stroke. A
check valve and orifice system in the bottom of the
NOTE: TYPICAL MAST ASSEMBLY IS SHOWN rod assembly keeps the oil at the correct level. When
HERE. the cylinder is fully extended, excess oil above the
piston is forced through the check valve. This ac-
1. OUTER WELDMENT tion allows the cylinder to fully extend. See Cylinder
2. INTERMEDIATE WELDMENT
3. INNER WELDMENT Cushion During Lifting Sequence.
4. FREE-LIFT CHAIN
5. MAIN LIFT CHAIN(S) Each main lift cylinder has an orifice system and a
6. FREE-LIFT CYLINDER check valve in the bottom of the rod assembly. When
7. MAIN LIFT CYLINDER(S) the cylinder is fully extended, excess oil between the
8. LOWERING CONTROL VALVE (EXTERNAL) rod end and the gland is forced through the check
valve. This action allows the cylinder to fully extend.
Figure 11. Three-Stage Mast
The orifice system provides a hydraulic cushion when
the cylinder reaches the bottom of its stroke. See
Cylinder Cushion During Lowering Sequence.
9
Three-Stage Mast, Full Free-Lift (FFL) 4000 SRM 521
1. LIFT CYLINDER 7. INTERMEDIATE WELDMENT

2. FREE-LIFT CYLINDER 8. INNER WELDMENT
3. LOWERING CONTROL VALVE (INTERNAL) 9. MAIN LIFT CHAIN
4. LOWERING CONTROL VALVE (EXTERNAL) 10. CARRIAGE
5. TO/FROM MAIN CONTROL VALVE 11. FREE-LIFT CHAIN
6. OUTER WELDMENT
Figure 12. Operation of Three-Stage Mast, Full Free-Lift (FFL)
10
4000 SRM 521 Cylinder Cushion During Lifting Sequence
Cylinder Cushion During Lifting Sequence

There is hydraulic oil on the rod side of the piston
of the free-lift cylinder. As the cylinder rod extends,
the hydraulic oil on the rod side flows to the base of
the cylinder through the larger hole and the internal
check valve. When the cylinder rod extends to the
last 25 mm (1 in.) of its stroke, the retainer at the top
of the cylinder closes the larger hole. During the last
25 mm (1 in.) of the cylinder stroke, the remainder
of the hydraulic oil must flow through the orifice to
the internal check valve. This action increases the
hydraulic pressure so the main lift cylinders begin to
extend. See Figure 13.
The hydraulic action at the end of the free-lift stroke

provides a cushion effect for the free-lift cylinder and
a smooth transition between the free-lift phase and
the channel extension phase. All masts with a free-
lift cylinder in this section use this design.
1. CYLINDER ROD
2. CYLINDER SHELL
3. LARGER HOLE
4. ORIFICE (SMALLER HOLE)
5. PISTON
6. INTERNAL CHECK VALVE
Figure 13. Free-Lift Cylinder Piston
11
Cylinder Cushion During Lowering Sequence 4000 SRM 521
Cylinder Cushion During Lowering Sequence

NOTE: Internal check valve is not used on the two-
stage FFL mast.
When the main lift cylinders retract, the hydraulic oil

flows out of the cylinder through the hydraulic port
until the piston seal moves past hydraulic port. Dur-
ing the last 20 mm (0.79 in.) of the retraction stroke,
the hydraulic oil must flow through the orifice. See
Figure 14. This action causes the cylinder rod to
move much more slowly at the end of the retraction
stroke. This cushion effect prevents a sudden stop
at the end of the lowering sequence, which causes
smoother operation during lowering. All masts in
this section use this design in the main lift cylinders.
1. CYLINDER ROD 5. HYDRAULIC PORT

2. CYLINDER SHELL 6. ORIFICE
3. PISTON 7. PISTON SEAL
4. INTERNAL CHECK
VALVE
Figure 14. Main Lift Cylinder Piston
12
4000 SRM 521 5/04

(11/03)(3/03)(1/02)(5/01)(2/01)(6/96)(10/95)(3/95)(11/94)(7/94)(3/94) Printed in United Kingdom
MAST
REPAIRS
H/S/1.50-1.75XM (H/S/25-35XM) [D001, C010, D010, E001];
E1.50-1.75XM (E25-35XM, E25-35XM 2) [D114];
H/S/2.00XMS (H/S/40XMS) [D001, C010, D010, E001];
E2.00XMS (E40XMS, E40XM 2S) [ D114];
H/S/2.00-3.20XM (H/S/40-65XM) [D177, D187];
E2.00-3.20XM (E40-65XM, E40-65XM 2) [F108];
J2.00-3.20XM (J40-60XM, J40-60XM 2) [A216];
J2.00-3.20XM (J40-65Z) [A416];
S/J2.00-3.00XL with Mast S/N C507, C508, C509, C562, C563, and C564
(S/E/J40-60XL) [A187, B187, C187, C108, B168];
J1.60-2.00XMT (J30-40XMT) [C160, F160];
H2.00-3.20XM (H45-65XM) [H177]; J30-40XMT 2 [H160];
E1.50-2.00XM (E25-35Z, E40ZS) [E114];
E2.00-3.20XM (E45-65Z) [G108]; J1.60-2.00XMT (J30-40ZT) [J160]
PART NO. 897507 4000 SRM 522

SAFETY PRECAUTIONS

trucks.
nance section.
manual:
WARNING
CAUTION
Mast Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Safety Procedures When Working Near Mast.................................................................................................. 1
Forks Repair....................................................................................................................................................... 3
Remove ........................................................................................................................................................... 3
Install ............................................................................................................................................................. 4
Carriages Repair ................................................................................................................................................ 4
Standard Carriage, Remove.......................................................................................................................... 4
Hang-On Sideshift Carriage, Remove .......................................................................................................... 5
Standard Carriage and Hang-On Sideshift Carriage, Repair..................................................................... 6
Standard Carriage, Install ............................................................................................................................ 6
Hang-On Sideshift Carriage, Install ............................................................................................................ 7
Integral Sideshift Carriage ........................................................................................................................... 7
Remove....................................................................................................................................................... 7
Clean and Inspect...................................................................................................................................... 9
Repair......................................................................................................................................................... 9
Install ......................................................................................................................................................... 10
Mast Repair........................................................................................................................................................ 10
Remove ........................................................................................................................................................... 10
Two-Stage LFL and Two-Stage FFL Masts, Disassemble ........................................................................... 12
Three-Stage FFL Mast .................................................................................................................................. 19
Disassemble ............................................................................................................................................... 19
Mast and Chains, Clean and Inspect ....................................................................................................... 22
Two-Stage LFL and Two-Stage FFL Mast, Assemble.................................................................................. 23
Three-Stage FFL Mast, Assemble ................................................................................................................ 24
Install ............................................................................................................................................................. 26
Lift Cylinders Repair ......................................................................................................................................... 27
Main Lift Cylinders, Remove ........................................................................................................................ 27
Free-Lift Cylinder, Remove ........................................................................................................................... 27
Lift Cylinders, Disassemble .......................................................................................................................... 28
Lift Cylinders, Assemble ............................................................................................................................... 28
Main Lift Cylinders, Install .......................................................................................................................... 31
Free-Lift Cylinder, Install ............................................................................................................................. 32
Header Hose Arrangements .............................................................................................................................. 32
Two-Stage LFL Mast, New Hose Install ...................................................................................................... 32
Two-Stage LFL Mast, Adjust Hoses After Installation ............................................................................... 38
Two-Stage FFL Mast, New Hose Install ...................................................................................................... 38
Two-Stage FFL Mast, Adjust Hoses After Installation ............................................................................... 43
Three-Stage FFL Mast, New Hose Install ................................................................................................... 45
Three-Stage FFL Mast, Adjust Hoses After Installation ............................................................................ 55
Header Hose Arrangement................................................................................................................................ 56
Two-Stage LFL Mast, New Hose Install ...................................................................................................... 56
Two-Stage LFL Mast, Adjust Hoses After Installation ............................................................................... 56
Two-Stage FFL Mast, New Hose Install ...................................................................................................... 60
Two-Stage FFL Mast, Adjust Hoses After Installation ............................................................................... 65
Three-Stage FFL Mast, New Hose Install ................................................................................................... 67
Three-Stage FFL Mast, Adjust Hoses After Install..................................................................................... 72
Lift and Tilt System Leak Check ...................................................................................................................... 76
Lift Cylinders Leak Check ............................................................................................................................ 76
Tilt Cylinders Leak Check ............................................................................................................................ 76
Tilt Cylinders Adjustment................................................................................................................................. 77
Lift Chains Adjustment ..................................................................................................................................... 78

Table of Contents Mast

Mast Adjustment ............................................................................................................................................... 80
Carriage Adjustment ......................................................................................................................................... 82
H/S/1.50-1.75XM (H/S/25-35XM) [D001, C010, D010, E001];

E1.50-1.75XM (E25-35XM, E25-35XM 2) [D114];
H/S/2.00XMS (H/S/40XMS) [D001, C010, D010, E001];
E2.00XMS (E40XMS, E40XM 2S) [ D114];
H/S/2.00-3.20XM (H/S/40-65XM) [D177, D187];
E2.00-3.20XM (E40-65XM, E40-65XM 2) [F108];
J2.00-3.20XM (J40-60XM, J40-60XM 2) [A216];
J2.00-3.20XM (J40-65Z) [A416];
S/J2.00-3.00XL with Mast S/N C507, C508, C509, C562, C563, and C564
(S/E/J40-60XL) [A187, B187, C187, C108, B168];
J1.60-2.00XMT (J30-40XMT) [C160, F160];
H2.00-3.20XM (H45-65XM) [H177];
J30-40XMT 2 [H160];
E1.50-2.00XM (E25-35Z, E40ZS) [E114];
E2.00-3.20XM (E45-65Z) [G108];
J1.60-2.00XMT (J30-40ZT) [J160]
ii
4000 SRM 522 Safety Procedures When Working Near Mast
General
4000 SRM 521 for the description and operation of
WARNING the masts.
Before working on or near the mast, see Safety
Procedures When Working Near Mast in this NOTE: Hoses have a service life that is determined
section. by application and time. All hoses must be inspected
at the intervals specified in the Maintenance Sched-
This section has the repair procedures for the ule for the hydraulic system. Install a new hose if the
Two-Stage, Limited Free-Lift (LFL); Two-Stage, Full hose is worn, damaged, soft or hard, and no longer
Free-Lift (FFL); Three-Stage, Full Free-Lift (FFL) flexible. If necessary, make a comparison to a new
masts; and for the sideshift carriages. Carriage hose that is the correct replacement for the hose you
Adjustment and Troubleshooting are at the end of are inspecting.
this section. See the section Mast, Description
Safety Procedures When Working Near Mast

The following procedures MUST be used when in- OR
specting or working near the mast. Additional pre-
cautions and procedures can be required when re- • If parts of the mast must be in a raised po-
pairing or removing the mast. sition, install a safety chain to restrain the
moving parts of the mast. Connect moving
parts to a part that does not move. Follow
WARNING these procedures:
Mast parts are heavy and can move. Distances
between parts are small. Serious injury or 1. Put the mast in a vertical position.
death can result if part of the body is hit by
parts of the mast or the carriage. 2. Raise the mast to align the bottom crossmem-
• Never put any part of the body into or under ber of the weldment that moves in the outer
the mast or carriage unless all parts are com- weldment with a crossmember on the outer
pletely lowered or a safety chain is installed. weldment. On the two-stage and free-lift mast,
Also make sure the power is off and the key the moving part is the inner weldment. On the
is removed. Put a DO NOT OPERATE tag in three-stage mast, it is the intermediate weld-
the operator’s compartment. ment. See Figure 1.
• Be careful of the forks. When the mast is 3. Use a 9.5 mm (3/8 in.) minimum safety chain
raised, the forks can be at a height to cause with a hook to fasten the crossmembers together
an injury. so the movable member cannot lower. Put the
• DO NOT climb on the mast or lift truck at any hook on the back side of the mast. Make sure
time. Use a ladder or personnel lift to work the hook is completely engaged with a link in
on the mast. the chain. Make sure the safety chain does not
• DO NOT use blocks to support the mast weld- touch lift chains or chain sheaves, tubes, hoses,
ments nor to restrain their movement. fittings, or other parts on the mast.
• Mast repairs require disassembly and re-
moval of parts and can require removal of 4. Lower the mast until there is tension in the
the mast or carriage. Follow the repair pro- safety chain and the free-lift cylinder (two-stage
cedures in the correct Service Manual for full free-lift and three-stage masts only) is com-
the mast. pletely retracted. If running, stop the engine.
Apply the parking brake. Install a DO NOT
WHEN WORKING NEAR THE MAST ALWAYS: REMOVE tag on the safety chain(s).
• Lower the mast and carriage completely.
Push the lift/lower control lever forward and NOTE: After lowering or restraining the mast, shut
make sure there is no movement in the mast. off the power and remove the key. Put a DO NOT
Make sure all parts of the mast that move are OPERATE tag in the operator’s compartment.
fully lowered.
1
Safety Procedures When Working Near Mast 4000 SRM 522
A. TWO-STAGE LFL MAST B. TWO-STAGE FFL MAST C. THREE-STAGE FFL MAST

1. OUTER WELDMENT 4. HOOK 7. CROSSMEMBER
2. INNER WELDMENT 5. FREE-LIFT CYLINDER
3. INTERMEDIATE WELDMENT 6. CROSSMEMBER
Figure 1. Two-Stage LFL, Two-Stage FFL, and Three-Stage FFL Masts
2
4000 SRM 522 Forks Repair
Forks Repair
The forks are held on the carriage by hooks. The the fork removal notch. See Figure 3. Lower the car-
forks are kept in position by latch pins that fit riage further so the top hook of the fork is disengaged
through the top fork hooks and into slots in the top from the top carriage bar. Move the carriage away
bar carriage. Always check that the latch pins for from the fork, or use a lifting device to move the fork
the forks keep the forks in position on the carriage. away from the carriage.
Replace damaged latch pins parts. The forks can be
removed from the carriage by aligning the forks with
the fork removal notch. The fork removal notch is in
the bottom bar of the carriage.
REMOVE
WARNING
Do NOT try to remove a fork without a lifting
device. Each hook fork for these lift trucks can
weigh 45 to 115 kg (99 to 254 lb).
A fork can be removed from the carriage for replace-

ment of the fork or other maintenance. Slide the fork
to the fork removal notch in the bottom bar of the car- 1. CARRIAGE BARS 3. BLOCKS
riage. See Figure 2 and Figure 3. Lower the fork onto 2. HOOK FORK
blocks so the bottom hook of the fork moves through
Figure 2. Hook Fork Removal
A. EARLIER MODELS B. LATER MODELS

1. FORKS 6. LEVER
2. CARRIAGE 7. WASHER
3. LOAD BACKREST EXTENSION 8. SPRING
4. FORK REMOVAL NOTCH 9. PIN
5. LATCH PIN ASSEMBLY 10. KNOB
Figure 3. Carriage and Forks
3
Carriages Repair 4000 SRM 522
INSTALL removal notch. Slide the fork on the carriage so both

upper and lower hooks engage the carriage bars. En-
Move the fork and carriage so the top hook on the gage the latch pin with a notch in the upper carriage
fork can engage the upper carriage bar. Raise the bar.
carriage to move the lower hook through the fork
Carriages Repair
STANDARD CARRIAGE, REMOVE
1. Put a one-quarter capacity load on the forks. The
load must give the carriage stability so the car-
riage cannot fall when it is disconnected from the
mast.
2. Lower the carriage and forks on blocks so the lift

chains become loose.
3. Remove the load backrest extension.
WARNING
When disconnecting the lift chains, keep con-
trol of the ends. Use wire to temporarily
connect the ends of the lift chains to the mast.
This procedure will prevent the lift chains
from falling from the sheaves and causing an
injury or damage.
4. Remove the pin from each chain anchor at the

carriage. See Figure 4. Disconnect the lift chains
from the carriage. Use wire to connect the ends
NOTE: TWO-STAGE LFL CARRIAGE SHOWN.
of the lift chains to a part of the mast. Make sure
the chains can move freely when the inner mast 1. CARRIAGE 6. CHAIN PIN
weldment is raised. 2. SNAP RING 7. COTTER PIN
3. SHIM 8. ANCHOR PIN
4. LOAD ROLLER 9. SPACER
WARNING 5. CHAIN ANCHOR
To help prevent possible injury, make sure the
carriage is stable when the inner mast weld- Figure 4. Standard Carriage
ment is above the load rollers of the carriage.
6. Move the lift truck away from the carriage. Com-
5. Use the lift cylinders to raise the inner mast pletely lower the inner mast weldment so it can-
weldment. If the hydraulic system cannot be not move.
used, disconnect the lift cylinders from the inner
7. Connect a lifting device to the carriage. Remove
or intermediate mast weldment. Connect a crane
the load from the forks with another lift truck.
[the capacity of the crane must be at least 681 kg
Lower the carriage to the floor so the load rollers
(1501 lb)] to the top of the inner mast weldment.
are facing up.
Carefully raise the inner mast weldment until it
is above the load rollers of the carriage. 8. If the forks are removed, use a lifting device to
put the carriage on the floor so the load rollers
are up.
4
4000 SRM 522 Carriages Repair
HANG-ON SIDESHIFT CARRIAGE, bracket and cylinder will stay on the standard
REMOVE carriage. Remove the bearings.
1. Lower the carriage completely. Remove the forks

WARNING
and the load backrest extension.
Hydraulic oil is hot after system operation and
2. Connect a crane [the capacity of the crane must can cause burns. Do not disconnect any hy-
be at least 681 kg (1501 lb)] to the lifting eye on draulic lines of the system until the oil for the
the sideshift carriage. See Figure 5. system is cool and the pressure is relieved.
3. Remove the two upper capscrews from the lower 5. Disconnect the hydraulic lines at the sideshift
apron. Slowly loosen the two bottom capscrews, cylinder. Put caps on the open hydraulic lines.
but do not remove them. The slotted holes will al- Remove the cylinder support bracket from the
low the lower apron to move down so the sideshift standard carriage. If necessary, remove the
carriage can be removed. threaded rods and shims in order to remove the
sideshift cylinder.
4. Carefully lift the sideshift carriage from the stan-
dard carriage. The sideshift cylinder support
A. HYDRAULIC CONNECTIONS - TWO-STAGE, B. HYDRAULIC CONNECTIONS - TWO-STAGE,

FULL FREE-LIFT AND THREE-STAGE, FULL LIMITED FREE-LIFT
FREE-LIFT
1. TOP BEARING 7. UPPER APRON
2. CYLINDER SUPPORT BRACKET 8. BOTTOM BEARING
3. THREADED ROD 9. LOWER APRON
4. SHIM 10. LIFTING EYE
5. SIDESHIFT CYLINDER 11. SHIM STRIP
6. GREASE FITTING
Figure 5. Hang-On Sideshift Carriage
5
STANDARD CARRIAGE AND HANG-ON d. Install the piston and rod in the shell. Ap-
SIDESHIFT CARRIAGE, REPAIR ply Loctite® 242 to the threads of the retain-
ers. Install the retainers and tighten them to
NOTE: The carriage can have four or six load rollers. 27 N•m (20 lbf ft).
When the carriage has four load rollers, shims are
used behind all of the load rollers. When the carriage 4. Replace the cylinder rod seals as follows:
has six load rollers, shims are installed on the bottom
a. Clamp the cylinder in a soft-jawed vise. DO
and middle rollers only.
NOT clamp on the cylinder shell.
1. If any of the load rollers must be replaced, make
b. With the cylinder rod centered, unscrew the
a note of the location and number of the shims.
retainer from each end of the cylinder. Slide
Install the shims, load rollers, and snap rings.
the retainers off the cylinder rod.
See Carriage Adjustment for correct adjustment
of the load rollers. NOTE: If new retainers that are already assembled
with seals are being installed, proceed to Step f.
2. If the carriage aprons have any protruding welds
or damaged notches, repair by grinding, filing, or c. Remove the seals and O-ring from each re-
welding. tainer with a brass O-ring tool. DO NOT
scratch the grooves.
3. The repair procedure for the sideshift cylinder is
as follows (see Figure 5 and Figure 6):
WARNING
a. Remove the retainers from the shell. Pull the Cleaning solvents may be flammable and toxic
rod from the shell. and can cause severe skin irritation. When
using cleaning solvents, always follow the
solvent manufacturer’s recommended safety
precautions.
d. Clean the retainers and the cylinder rod with

cleaning solvent. Lubricate the new seals
and O-rings with hydraulic oil.
e. Install the seals into the retainer grooves.

Form the seals into a "kidney" shape to ease
placement into the groove. Note the direc-
tion of the rod seals. Pressure seals are in-
stalled with the lip toward the pressure
side of the cylinder.
f. Apply a film of hydraulic oil to the inside

1. SHELL 5. RETAINER of the retainers. Carefully slide them onto
2. O-RING 6. WIPER the cylinder rod. Tighten the retainers to
3. BACKUP RING 7. PISTON AND ROD 165 N•m (122 lbf ft).
4. ROD SEAL 8. PISTON SEAL
Figure 6. Sideshift Cylinder STANDARD CARRIAGE, INSTALL
b. Replace seals, O-rings, or backup rings as 1. Use the hydraulic system of the lift truck or a
necessary. Use the installation guides to pre- crane to raise the inner mast weldment. If the
vent damage to the seals. hydraulic system cannot be used, disconnect the
lift cylinders from the inner or intermediate mast
c. Lubricate all internal parts with clean hy- weldment. Connect a crane [the capacity of the
draulic oil. crane must be at least 681 kg (1501 lb)] to the top
of the inner mast weldment. Carefully raise the
inner mast weldment until it is above the load
rollers of the carriage.
6
2. Move the lift truck toward the carriage until the crane must be at least 908 kg (2002 lb)] to the
inner mast weldment is aligned with the carriage lifting eye. Install the sideshift carriage on the
rollers. Carefully lower the inner mast weldment standard carriage. Put blocks under the bottom
until it engages all of the load rollers. apron of the sideshift carriage so the bottom
bearing moves tight against the standard car-
3. Check the clearance of the load rollers. See Car- riage when the lifting device is lowered.
riage Adjustment in this section.
Install the two top capscrews into the sideshift
4. Connect the lift chains to the chain anchors at the carriage. Tighten the capscrews to the following
carriage. Use new cotter pins in the anchor pins. torque:
Adjust the lift chains as described in Carriage • On H/S1.50-1.75XM, H/S2.00XMS (H/S25-
Adjustment in this section. 35XM, H/S40XMS), E1.50-1.75XM (E25-
35XM, E25-35XM 2) [D114], E2.00XMS
5. Install the backrest on the sideshift carriage.
(E40XMS, E40XM 2S [D114], E1.50-2.00XM
Tighten the capscrews to 195 N•m (144 lbf ft).
(E25-35Z, E40ZS) [E114], H/S2.00-2.75XM
(H/S40-55XM), S/E/J2.00-2.50XL (S/E/
HANG-ON SIDESHIFT CARRIAGE,
J40-50XL), J1.60-2.00XMT (J30-40XMT),
INSTALL J2.00-2.50XM (J40-50XM) [A216], and
1. Install the sideshift cylinder in the cylinder sup- J2.00-2.50XM (J40-50Z) [A416] units, tighten
port bracket. See Figure 5. Use an equal num- all of the capscrews to 435 N•m (321 lbf ft).
ber of shims on both sides of the cylinder to limit • On H/S3.00-3.20XM (H/S60-65XM), J3.00-
side-to-side movement within the bracket. Maxi- 3.20XM (J60XM) [A216], J3.00-3.20XM (J60Z)
mum movement is 0.6 mm (0.024 in.). Install the [A416], E2.00-3.20XM (E45-65Z) [G108], and
threaded rods to hold the cylinder in position and S/E/J3.00XL (S/E/J60XL) units, tighten all of
tighten to 18 N•m (159 lbf in). the capscrews to 755 N•m (557 lbf ft).
2. Install the cylinder support bracket on the stan- 8. Install the load backrest extension on the
dard carriage. Make sure the bracket is engaged sideshift carriage. Tighten the capscrews to
in the center notch in the top carriage bar. 195 N•m (144 lbf ft).
3. Connect the hydraulic lines to the sideshift cylin- 9. Remove the lifting device. Lubricate the top
der. See Figure 5. Lubricate the ends of the cylin- bearings at the grease fittings.
der rod with multipurpose grease.
INTEGRAL SIDESHIFT CARRIAGE
4. Install the top bearing on the cylinder support
bracket. Lubricate only the outer surface of the Remove
bearing with multipurpose grease.
1. Lower the carriage completely. Remove the forks
5. Connect the top and bottom aprons by installing and the load backrest extension. See Figure 3
the two bottom capscrews. Do NOT tighten the and Figure 7.
capscrews. Lubricate only the outer surface of
the bottom bearing with multipurpose grease. WARNING
Install the bottom bearing in the lower apron. Hydraulic oil is hot after system operation and
6. Install the shim strips under the bottom bearing can cause burns. Do not disconnect any hy-
strip (be sure the shims are seated between the draulic lines of the system until the oil for the
shim stops) so the bottom bearing strip will just system is cool and the pressure is relieved.
clear the lower lip of the standard carriage bar 2. Disconnect the hydraulic lines at the sideshift
when the lower apron is brought into position. cylinder. Put caps on the open hydraulic lines.
7. Make sure the standard carriage is completely 3. Remove the lower mounting hooks.
lowered. Connect a crane [the capacity of the
7
NOTE: TWO AND THREE-STAGE FFL IS SHOWN.

1. INNER CARRIAGE 12. LUBE FITTING
2. OUTER FRAME 13. PIN
3. SIDESHIFT CYLINDER 14. CHAIN ANCHOR
4. UPPER BEARING 15. SNAP RING
5. LOWER BEARING 16. PIN
6. LOWER HOOK 17. COTTER PIN
7. CAPSCREW 18. LOAD ROLLER
8. WASHER 19. SHIMS
9. CLEVIS PIN 20. SPACER
10. HAIRPIN 21. SNAP RING
11. PIN 22. SPACER
Figure 7. Integral Sideshift Carriage
8
4. Use a crane with a capacity of at least 450 kg

(992 lb) to lift the outer frame away from the in-
ner frame. Lay the outer frame flat on a pallet or
workbench.
5. If the sideshift cylinder or the bearings are to be

serviced, remove the capscrews and the cylinder
assembly from the inner frame.
Clean and Inspect

1. Inspect the lower mounting hooks for wear. Re-
place the hooks if they are worn beyond the wear
limit. The wear limit clearance range is 0.8 mm
(1/32 in.) minimum and 1.6 mm (1/16 in.) maxi-
mum. See Figure 7.
2. Clean and inspect the carriage bars for damage

and smoothness. Ensure the bars are parallel
and the ends are flush.
1. CYLINDER SHELL 3. O-RING
3. Clean the bearing areas. Inspect the sideshift AND ROD 4. RETAINER
bearings for wear as follows: 2. SEAL 5. WIPER
a. Remove the upper bearings from the upper Figure 8. Integral Sideshift Cylinder
apron. If either upper bearing is worn to
less than 2.5 mm (3/32 in.) thickness, re- 3. Replace the cylinder rod seals as follows:
place both upper bearings by driving the up-
per bearings from the upper apron. a. Clamp the cylinder in a soft-jawed vise. DO
NOT clamp on the cylinder shell.
b. Remove the lower bearings from the lower
carriage bar. If either lower bearing is worn b. With the cylinder rod centered, unscrew the
to less than 2.5 mm (3/32 in.) thickness, re- retainer from each end of the cylinder. Slide
place both lower bearings by prying the lower the retainers off the cylinder rod.
bearings from the lower carriage bar. NOTE: If new retainers that are already assembled
4. Inspect the sideshift cylinder. Replace the en- with seals are being installed, proceed to Step f.
tire cylinder assembly if a cylinder rod is bent or c. Remove the seals and O-ring from each re-
scored or if there is damage on the outside of the tainer with a brass O-ring tool. DO NOT
cylinder shell that could impair performance or scratch the grooves.
cause leaks under pressure. See Figure 8.
Repair WARNING
Cleaning solvents may be flammable and toxic
1. If any of the load rollers must be replaced, make and can cause severe skin irritation. When
a note of the location and number of the shims. using cleaning solvents, always follow the
Install the shims, load rollers, and snap rings. solvent manufacturer’s recommended safety
See Carriage Adjustment for correct adjustment. precautions.
2. If the carriage bars have any protruding welds d. Clean the retainers and the cylinder rod with
or damaged notches, repair by grinding, filing, cleaning solvent. Lubricate the new seals
or welding. and O-rings with hydraulic oil.
9
Mast Repair 4000 SRM 522
e. Install the seals into the retainer grooves. 1. If necessary, install the lower sideshift bearings.
Form the seals into a "kidney" shape to ease Then install the upper sideshift bearings. Lubri-
placement into the groove. Note the direc- cate the upper and lower sideshift bearings with
tion of the rod seals. Pressure seals are in- chassis grease. See Figure 7.
stalled with the lip toward the pressure
side of the cylinder. 2. If necessary, install the sideshift cylinder.
f. Apply a film of hydraulic oil to the inside 3. Use a crane with a capacity of at least 450 kg
of the retainers. Carefully slide them onto (992 lb) to install the outer frame on the inner
the cylinder rod. Tighten the retainers to frame.
165 N•m (122 lbf ft).
4. Install the lower mounting hooks. For proper
sideshift operation, make sure there is 0.8 to
Install
1.6 mm (1/32 to 1/16 in.) clearance between the
NOTE: Use a wood block or a plastic hammer to fully bottom of the hooks and the outer frame.
seat the upper bearings onto the upper carriage bar.
5. Connect the hydraulic lines to the sideshift cylin-
Proper lower hook clearance requires the upper bear-
der.
ings be fully seated.
6. Install the backrest on the sideshift carriage.
Tighten the capscrews to 195 N•m (144 lbf ft).
7. Install the forks.
Mast Repair
REMOVE WARNING
WARNING can cause burns. Do not disconnect any hy-
The mast is heavy. The mast can weigh approx- draulic hoses until the oil in the system is cool.
imately 907.2 kg (2000 lb). Make sure all lift-
ing devices (hoists, cables, chains, slings, etc.) 2. Put a drain pan under the area of the hydraulic
are suitable and of adequate capacity to lift the fittings. Disconnect the hydraulic line at the ex-
mast. ternal lowering control valve on the outer mast
weldment.
NOTE: If the mast needs to be disassembled, remove
the forks and carriage. If only the lift cylinders need WARNING
to be removed for repair, the mast does not need to be
Use a driver, NOT your fingers, to push the an-
removed from the lift truck. See the procedures for
chor pins from the clevises on the tilt cylinders.
Lift Cylinders Repair.
The cylinder or mast can move and cause seri-
NOTE: The length of the lift chains must be checked ous injury.
before the mast is removed. See Step 2 in Mast and
3. Remove the cotter pins and anchor pins or the
Chains, Clean and Inspect.
capscrews, washers, and anchor pins at the tilt
1. Fully lower all of the mast weldments and the cylinder mounts on the outer mast weldment.
carriage. Tilt the mast fully forward. Connect a
NOTE: To perform the next two steps, the lift truck
crane with a capacity of at least 1600 kg (3527 lb)
must be raised. See the Operator Manual or Pe-
to the top of the mast using chains. Make sure all
riodic Maintenance Manual for your lift truck for
the mast weldments are fastened together. Make
instructions on how to put a lift truck on blocks.
sure the chains will not damage the sheaves, tub-
ing, or other parts of the mast. 4. On the H/S2.00-3.20XM (H/S40-65XM),
E2.00-3.20XM (E40-65XM, E40-65XM 2)
(F108), E2.00-3.20XM (E45-65Z) (G108)
10
4000 SRM 522 Mast Repair
J2.00-3.20XM (J40-60XM, J40-60XM 2) (A216),

and J2.00-3.20XM (J40-65Z) (A416), see Fig-
ure 9, remove the capscrews that hold the outer
mast weldment to the pivot pins at the mounts.
5. On the H/S1.50-1.75XM, H/S2.00XMS (H/S25-

35XM, H/S40XMS), E1.50-1.75XM (E25-35XM,
E25-35XM 2) (D114), E2.00XMS (E40XMS,
E40XM SS (D114), E1.50-2.00XM (E25-35Z,
E40ZS) (E114), and J1.60-2.00XMT (J30-
40XMT), see Figure 10; on S/E/J2.00-3.00XL
(S/E/J40-60XL), see Figure 11; and on J1.60-
2.00XMT (J30-40ZT), see Figure 12, and remove
the capscrews that hold the retainer caps to the
mast mounts.
1. RETAINER CAP 6. SHIMS

2. SPACER 7. PIN
3. TILT CYLINDER 8. ROD END
4. OUTER MAST 9. O-RING
WELDMENT 10. CAPSCREW
5. BUSHING 11. FLAT WASHER
Figure 10. Mast Mounting H/S1.50-1.75XM,

H/S2.00XMS (H/S25-35XM, H/S40XMS),
E1.50-1.75XM (E25-35XM, E25-35XM 2) (D114),
E2.00XMS (E40XMS, E40XM 2S (D114),
E1.50-2.00XM (E25-35Z, E40ZS) (E114), and
J1.60-2.00XMT (J30-40XMT)
WARNING
The mast is heavy. The mast can weigh approx-
1. SPACER 7. O-RING imately 907.2 kg (2000 lb). Make sure all lift-
2. TILT CYLINDER 8. PIVOT PIN ing devices (hoists, cables, chains, slings, etc.)
3. OUTER MAST 9. DRIVE AXLE
WELDMENT HANGER (MAST are suitable and of adequate capacity to lift the
4. SHIMS MOUNT) mast.
5. PIN 10. COTTER PIN
6. ROD END 6. Use the crane to lift the mast assembly from the
lift truck. Put the mast on the floor so the back
Figure 9. Mast Mounting H/S2.00-3.20XM of the mast is toward the floor.
(H/S40-65XM), E2.00-3.20XM (E40-65XM,
E40-65XM 2) (F108), E2.00-3.20XM (E45-65Z)
(G108), J2.00-3.20XM (J40-60XM, J40-60XM 2)
(A216), and J2.00-3.20XM (J40-65Z) (A416),
11
cylinder. Remove the free-lift cylinder. Discon-

nect the free-lift chains at the crossmember.
1. RETAINER CAP 5. BUSHING

2. SPACER 6. SHIMS
3. TILT CYLINDER 7. PIN
4. OUTER MAST 8. ROD END
WELDMENT
Figure 11. Mast Mounting S/E/J2.00-3.00XL

(S/E/J40-60XL)
1. RETAINER CAP 6. NUT
TWO-STAGE LFL AND TWO-STAGE FFL 2. LOCKWASHER 7. PIN
3. TILT CYLINDER 8. ROD END
MASTS, DISASSEMBLE 4. OUTER MAST 9. WASHER
WELDMENT 10. CAPSCREW
5. BUSHING
WARNING
Hydraulic oil is hot after system operation and Figure 12. Mast Mounting J1.60-2.00XMT
can cause burns. Do not disconnect any hy- (J30-40ZT)
draulic lines of the system until the oil for the
system is cool and the pressure is relieved. WARNING
NOTE: If only the lift cylinders need to be removed Be careful when removing or installing snap
and repaired, see the procedures for Lift Cylinders rings. These snap rings can come loose dur-
Repair. When the mast has header hoses, see the ing removal or installation with enough force
procedures for the Header Hose Arrangements. to cause an injury. Always use the correct snap
ring pliers, and wear eye and face protection
1. Clean the area around the hydraulic fittings for during removal or installation.
the lift cylinders. Disconnect the fittings at the
lift cylinders and put caps on the open lines. 3. Remove the nut, bolt, and spacer at the mount
near the top of each main lift cylinder. Remove
2. Remove the chains and header hoses. On the the snap rings and washers from the top of
two-stage FFL mast, remove the brackets and each main lift cylinder. Disconnect the main lift
disconnect the hydraulic line for the free-lift chains at the mounts.
12
4. On the H/S2.00-3.20XM (H/S40-65XM), 30 cm (12 in.). Remove the strip bearings and
E2.00-3.20XM (E40-65XM, E40-65XM 2) (F108), load rollers from the top of the outer mast weld-
E2.00-3.20XM (E45-65Z) (G108), J2.00-3.20XM ment. Remove the load rollers from the bottom
(J40-60XM, J40-60XM 2) (A216), J2.00-3.20XM of the inner mast weldment. Make a note of each
(J40-65Z) (A416), and S/E/J2.00-3.00XL shim arrangement and load roller location. The
(S/E/J40-60XL), two-stage FFL mast, disconnect shim arrangements will be approximately the
the FFL supply tube and remove the hydraulic same during assembly.
fitting from the top of the left-hand main lift
cylinder.
WARNING
On the H/S1.50-1.75XM, H/S2.00XMS (H/S25- The mast is heavy. The mast can weigh ap-
35XM, H/S40XMS), E1.50-1.75XM (E25-35XM, proximately 681 kg (1501 lb). Make sure all lift-
E25-35XM 2) (D114), E2.00XMS (E40XMS, ing devices (hoists, cables, chains, slings, etc.)
E40XM 2S) (D114), E1.50-2.00XM (E25-35Z, are suitable and of adequate capacity to lift the
E40ZS) (E114), and J1.60-2.00XMT (J30- mast.
40XMT) two-stage FFL masts, disconnect the
FFL supply tube and remove the hydraulic fit- NOTE: When replacing the outer channel weldment,
ting from the top of the right-hand main lift copy the part number and date code information from
cylinder. the old channel and stamp that information on the
new channel with a letter R at the end to indicate
that it has been replaced.
WARNING
The mast weldment can slide when the mast is 7. Slide the inner mast weldment halfway out of
moved. A weldment that slides can cause in- the top of the outer mast weldment. Connect a
jury. crane [the capacity of the crane must be at least
681 kg (1501 lb)] to the center of the inner mast
5. Slide the inner mast weldment from the outer weldment. See Figure 15. Slide the inner mast
mast weldment approximately 30 cm (12 in.) to weldment out of the outer mast weldment until
disengage the main lift cylinders from the inner the mast stub shafts of the inner mast weldment
mast weldment. Remove the main lift cylinders are in the notches of the outer channels. Remove
from the outer mast weldment. See Figure 13 the inner mast weldment from the outer mast
and Figure 14. weldment.
6. Slide the inner mast weldment from the bot- 8. Remove the chain sheaves and disassemble them
tom of the outer mast weldment approximately as necessary for repair and cleaning.
13
Figure 13. Two-Stage, Limited Free-Lift Mast (Sheet 1 of 2)
14
Figure 13. Two-Stage, Limited Free-Lift Mast (Sheet 2 of 2)
15

A. MODELS H/S2.00-3.20XM (H/S40-65XM), E2.00-3.20XM (E40-65XM, E40-65XM 2) (F108), E2.00-3.20XM
(E45-65Z) (G108), J2.00-3.20XM (J40-60XM, J40-60XM 2) (A216), J2.00-3.20XM (J40-65Z) (A416), AND
S/E/J2.00-3.00XL (S/E/J40-60XL), SHOWN.
B. MODELS H/S1.50-2.00XMS (H/S25-40XMS), E1.50-2.00XMS (E25-40XMS, E25-40XM 2S) (D114),
E1.50-2.00XM (E25-35Z, E40ZS) (E114), AND J1.60-2.00XMT (J30-40XMT) SHOWN.
C. OLDER MODELS.
1. OUTER MAST WELDMENT 14. STAR WASHER
2. LOAD ROLLER 15. HOUSING
3. SHIM 16. LOWERING CONTROL VALVE (EXTERNAL)
4. SNAP RING 17. INNER MAST WELDMENT
5. O-RING 18. PIN (2)
6. SHIM(S) 19. SPACER
7. STRIP BEARING 20. CHAIN SHEAVE
8. WASHER 21. PIN
9. MAIN LIFT CYLINDER 22. CAPSCREW
10. MAIN LIFT CHAIN 23. NUT
11. CHAIN ANCHOR 24. HOSE
12. LOWERING CONTROL VALVE (INTERNAL) 25. PLUG
13. SPRING
16
Figure 14. Two-Stage, Full Free-Lift Mast (Sheet 1 of 2)
17
Figure 14. Two-Stage, Full Free-Lift Mast (Sheet 2 of 2)
18

C. OLDER MODELS.
1. OUTER MAST WELDMENT 15. LOWERING CONTROL VALVE (EXTERNAL)
2. LOAD ROLLER 16. INNER MAST WELDMENT
3. SHIM 17. FREE-LIFT CHAIN
4. SNAP RING 18. CHAIN ANCHOR
5. O-RING 19. FREE-LIFT CYLINDER
6. SHIM(S) 20. CYLINDER BRACKET
7. STRIP BEARING 21. HOSE
8. WASHER 22. CROSSHEAD
9. LEFT-HAND MAIN LIFT CYLINDER 23. CHAIN GUARD
10. RIGHT-HAND MAIN LIFT CYLINDER 24. PLUG
11. STAR WASHER 25. CAPSCREW
12. SPRING 26. SPACER
13. LOWERING CONTROL VALVE (INTERNAL) 27. NUT
14. HOUSING 28. TUBE
2. Disconnect and remove the hydraulic lines for
the main free-lift cylinder. Remove the brackets
for the main free-lift cylinder. Remove the main
free-lift cylinder.
3. Disconnect the main lift chains from the chain

anchors near the top of the main lift cylinders.
Disconnect the other end of the main lift chains
at the bottom of the inner mast weldment. Push
the inner mast weldment toward the bottom of
the mast assembly until the bottom load rollers
can be seen.
WARNING
The weldments can slide when the mast is
moved. A weldment that slides can cause in-
Figure 15. Inner Mast Weldment
jury. Use a crane to turn the mast slowly and
carefully.
THREE-STAGE FFL MAST
4. Remove the strip bearings at the top of the inter-
Disassemble mediate mast weldment. Remove the load rollers
at the bottom of the inner mast weldment. Re-
WARNING move the load rollers at the top of the intermedi-
Hydraulic oil is hot after system operation and ate mast weldment. Make a note of each shim ar-
can cause burns. Do not disconnect any hy- rangement and load roller location. The shim ar-
draulic lines of the system until oil for the sys- rangements will be approximately the same dur-
tem is cool and the pressure is relieved. ing assembly.
1. Disconnect the main free-lift chains at the cross-

member. See Figure 16.
19
Figure 16. Three-Stage, Full Free-Lift Mast (Sheet 1 of 2)
20

C. OLDER MODELS.
1. OUTER MAST WELDMENT 11. STAR WASHER 19. HOSE SHEAVE
2. LOAD ROLLER 12. SPRING 20. CHAIN ANCHOR
3. SHIM 13. LOWERING CONTROL VALVE 21. INNER MAST WELDMENT
4. SNAP RING (INTERNAL) 22. FREE-LIFT CYLINDER
5. O-RING 14. HOUSING 23. CYLINDER BRACKET
6. SHIM(S) 15. LOWERING CONTROL VALVE 24. CAPSCREW
7. STRIP BEARING (EXTERNAL) 25. SPACER
8. WASHER 16. CHAIN SHEAVE 26. NUT
9. MAIN LIFT CYLINDER 17. INTERMEDIATE MAST 27. HOSE
10. LIFT CHAIN WELDMENT 28. FLOW CONTROL FITTING
18. FREE-LIFT CYLINDER TUBE
Figure 16. Three-Stage, Full Free-Lift Mast (Sheet 2 of 2)
21
(1501 lb) to the center of the intermediate mast

WARNING weldment. See Figure 15. Slide the intermedi-
The mast is heavy. The mast can weigh ap- ate mast weldment out of the outer mast weld-
proximately 681 kg (1501 lb). Make sure all lift- ment until the stub shafts are in the notches of
ing devices (hoists, cables, chains, slings, etc.) the outer mast weldment. Remove the interme-
are suitable and of adequate capacity to lift the diate mast weldment from the outer mast weld-
mast. ment.
5. Slide the inner mast weldment halfway out of 10. Disassemble the chain sheaves as necessary for
the top of the intermediate mast weldment. Con- repair and cleaning. Remove the hydraulic lines
nect a crane with a capacity of at least 681 kg and fittings from the weldments as necessary.
(1501 lb) to the center of the inner mast weld-
ment. See Figure 15. Slide the inner mast weld- Mast and Chains, Clean and Inspect
ment out of the intermediate mast weldment un-
til the stub shafts are in the notches of the inter- 1. Inspect the chain sheaves and load rollers for
mediate mast weldment. Remove the inner mast wear or damage. Do NOT use steam to clean the
weldment from the intermediate mast weldment. lift chains, sheaves, or load rollers. The bearings
in the sheaves and load rollers are sealed and lu-
WARNING bricated.
rings. These snap rings can come loose dur- WARNING
ing removal or installation with enough force Cleaning solvents may be flammable and toxic
to cause an injury. Always use the correct snap and can cause severe skin irritation. When
ring pliers, and wear eye and face protection using cleaning solvents, always follow the
during removal or installation. solvent manufacturer’s recommended safety
precautions.
6. Remove the snap rings and washers at the top of
the main lift cylinders. Remove the nut, bolt, and 2. Clean the lift chains with solvent. Remove all
spacer at the mount near the top of each main lift dirt and grease. Inspect the lift chains for wear
cylinder. or damage. The lift chains must be installed in
the mast and the mast must be installed on the
7. Push the intermediate mast weldment to disen- lift truck before they can be checked for correct
gage the main lift cylinders. Remove the main length.
lift cylinders.
8. Slide the intermediate mast weldment from the WARNING

bottom of the outer mast weldment approxi- Never replace only the worn section of a chain.
mately 30 cm (12 in.). Remove the strip bearings Replace the complete chain. Never replace
at the top of the outer mast weldment. Remove only one chain of a chain pair. Replace both
the snap rings and load rollers from both weld- chains.
ments. Make a note of each shim arrangement
and load roller location. The shim arrangements 3. A lift chain becomes longer when it is worn. If
will be approximately the same during assembly. a chain is 3% longer than a new lift chain, the
lift chain must be replaced. If a chain scale is
available, check the lift chain as shown in Fig-
WARNING ure 17. If a chain scale is not available, measure
The mast is heavy. The mast can weigh ap- 20 links of the lift chain. Compare the measure-
proximately 681 kg (1501 lb). Make sure all lift- ment with the lengths given in Figure 17. Lubri-
ing devices (hoists, cables, chains, slings, etc.) cate the chains with SAE 30 engine oil. The best
are suitable and of adequate capacity to lift the procedure is to soak them in engine oil.
mast.
4. Inspect the chain anchors and pins. Replace any
9. Slide the intermediate mast weldment halfway parts that are worn or damaged.
out of the top of the outer mast weldment. Con-
nect a crane with a capacity of at least 681 kg
22
using cleaning solvents, always follow the

solvent manufacturer’s recommended safety
precautions.
5. Clean the mast weldments with steam or solvent.
WARNING
Incorrect welding procedures can damage the
structure of the mast or cause wrong operation
of the mast. Obtain information from your Hys-
ter lift truck dealer before welding on the mast.
6. Inspect the sliding surfaces for wear or damage.

Inspect the load roller contact surfaces for wear
or damage. Inspect all welds for cracks.
TWO-STAGE LFL AND TWO-STAGE FFL

MAST, ASSEMBLE
WARNING
Pitch Total length Wear Limit The mast is heavy. The mast can weigh ap-
of 20 links The maximum proximately 681 kg (1501 lb). Make sure all lift-
(pitch) length of 20 ing devices (hoists, cables, chains, slings, etc.)
of new chain links are suitable and of adequate capacity to lift the
mast.
12.7 mm 254.0 mm 261.6 mm
(0.50 in.) (10.0 in.) (10.3 in.) NOTE: The shims for the load rollers keep the
15.9 mm 317.5 mm 327.0 mm mast weldments parallel and give correct clearance.
(0.63 in.) (12.5 in.) (12.9 in.) During assembly, the shim arrangement will be ap-
19.1 mm 381.0 mm 392.4 mm proximately the same as before disassembly. Check
(0.75 in.) (15.0 in.) (15.4 in.) the clearance and adjust the shims for wear or for
25.4 mm 508.0 mm 523.3 mm changes caused by repairs. The strip bearings are
(1.00 in.) (20.0 in.) (20.6 in.) also adjusted by using shims. See Carriage Adjust-
ment in this section for the adjustment procedures.
NOTE: THE INSTRUCTIONS FOR MEASURING
CHAIN WEAR ARE SHOWN ON THE CHAIN WEAR NOTE: When the mast has header hoses, see the pro-
SCALE. cedures for Header Hose Arrangements.
1. CHAIN WEAR SCALE 1. Connect a crane with a capacity of at least 681 kg

(1501 lb) to the center of the inner mast weld-
Figure 17. Lift Chains Check ment. Fit the stub shafts through the notches in
the outer mast weldment. Slide the inner mast
WARNING weldment into the outer mast weldment so the
stub shafts are seen at the top and bottom of the
Be careful when cleaning with steam. Steam
weldments. See Figure 13 and Figure 14.
can cause serious burns. Wear protective cloth-
ing, gloves, and eye protection. Never expose 2. Install the strip bearings and the shims on the
your skin to steam. outer mast weldment. See Figure 18. Apply
chassis lube to the bearing surface. Check the
WARNING clearance of the strip bearings as described in
Cleaning solvents may be flammable and toxic Carriage Adjustment.
and can cause severe skin irritation. When
23
Push the inner mast weldment to engage the

rods of the lift cylinders. Check the clearance
at the top of the lift cylinder mounts. Add
or remove washers at the left-hand cylinder
until it is even with the right-hand cylin-
der. Install the snap ring at the top of the
left-hand lift cylinder. Install the hydraulic
fitting on the right-hand cylinder.
6. Install the spacers, nuts, and bolts at the mounts

for the lift cylinders. Tighten the bolts to 53 N•m
(39 lbf ft).
7. Install the housing for the lowering control valve

on the outer mast weldment. Tighten the nuts for
the lowering control valve to 18 N•m (13 lbf ft).
Figure 18. Strip Bearings
Install the lowering control valve in the housing.
3. Install the load rollers and shims on both weld- Connect the hydraulic lines and fittings between
ments. Check the clearance of the load rollers as the lowering control valve and the main lift cylin-
described in Carriage Adjustment. ders.
4. To install the main lift cylinders on the two-stage 8. On the two-stage LFL mast, install the chain
LFL mast, push the inner mast weldment to en- sheaves at the inner mast weldment. On the
gage the rods of the lift cylinders. Install the H/S2.00-3.20XM (H/S40-65XM), E2.00-3.20XM
washer and snap ring. (E40-65XM, E40-65XM 2) (F108), E2.00-3.20XM
(E45-65Z) (G108), J2.00-3.20XM (J40-60XM,
NOTE: The clearance check and adjustment in either J40-60XM 2) (A216), J2.00-3.20XM (J40-65Z)
procedure for Step 5 is only an initial setup. The (A416), and S/E/J2.00-3.00XL (S/E/J40-60XL),
final check and adjustment is done after the mast is be sure to install both pins that hold the shaft
installed on the lift truck. for the chain sheave in position. Connect the
lift chains to the chain anchors at the main lift
5. To install the main lift cylinders on the two-stage cylinder mounts. Attach wires between the ends
FFL mast, perform the following procedure: of the lift chains and the crossmember to control
the lift chains during mast installation.
a. H/S2.00-3.20XM (H/S40-65XM), E2.00-
3.20XM (E40-65XM, E40-65XM 2) (F108), 9. On the two-stage FFL mast:
E2.00-3.20XM (E45-65Z) (G108), J2.00-
3.20XM (J40-60XM, J40-60XM 2) (A216), a. Install the free-lift cylinder in the mounts on
J2.00-3.20XM (J40-65Z) (A416), and the inner mast weldment. Install the brack-
S/E/J2.00-3.00XL (S/E/J40-60XL),: Install ets for the cylinder and tighten the bolts to
the washers at the top of the right-hand 53 N•m (39 lbf ft).
cylinder. Push the inner mast weldment to
engage the rods of the lift cylinders. Check b. Install the tubing or hoses that connect the
the clearance at the top of the lift cylinder free-lift cylinder to the main lift cylinder.
mounts. Add or remove washers at the
c. Connect the free-lift chains to the chain an-
right-hand cylinder until it is even with the
chors at the crossmember. Attach a wire be-
left-hand cylinder. Install the snap ring at
tween the end of the lift chain and the bottom
the top of the right-hand lift cylinder. Install
of the mast to control the lift chain during in-
the hydraulic fitting on the left-hand cylin-
stallation.
der.
b. H/S1.50-2.00XMS (H/S25-40XMS), E1.50- THREE-STAGE FFL MAST, ASSEMBLE

2.00XMS (E25-40XMS, E25-40XM 2S (D114),
NOTE: The shims for the load rollers keep the weld-
E1.50-2.00XM (E25-35Z, E40ZS) (E114), and
ments parallel and give correct clearance. During as-
J1.60-2.00XMT (J30-40XMT): Install the
sembly, the shim arrangement will be approximately
washers at the top of the left-hand cylinder.
24
the same as before disassembly. Check the clearance 6. Install the chain sheaves at the intermedi-
and adjust the shims for wear or for changes caused ate mast weldment. On the H/S2.00-3.20XM
by repairs. The strip bearings are also adjusted by (H/S40-65XM), E2.00-3.20XM (E40-65XM,
using shims. See Carriage Adjustment in this sec- E40-65XM 2) (F108), E2.00-3.20XM (E45-65Z)
tion for the adjustment procedures. (G108), J2.00-3.20XM (J40-60XM, J40-60XM 2)
(A216), J2.00-3.20XM (J40-65Z) (A416),
NOTE: When the mast has header hoses, see the pro- S/E/J2.00-3.00XL (S/E/J40-60XL), be sure to
cedures for Header Hose Arrangements. install both pins that hold the shaft for the chain
sheave in position.
1. Put the outer mast weldment on the floor with
the mast pivots toward the floor. See Figure 16. 7. Install the spacers, washers, nuts, and bolts at
Connect a crane with a capacity of at least 681 kg the mounts for the main lift cylinders. Tighten
(1501 lb) to the center of the intermediate mast the bolts to 53 N•m (39 lbf ft).
weldment. Fit the lower stub shafts of the inter-
mediate mast weldment into the notches in the 8. Connect a crane with a capacity of at least 681 kg
top of the outer mast weldment. Slide the in- (1501 lb) to the center of the inner mast weld-
termediate mast weldment into the outer mast ment. Slide the inner mast weldment into the in-
weldment so the stub shafts are seen at the top termediate mast weldment so the stub shafts are
and bottom of both weldments. seen at the top and bottom of both weldments.
NOTE: The load rollers must be in place before strip NOTE: The load rollers must be in place before bear-
bearing can be shimmed. ing strips can be shimmed.
2. Install the strip bearings and the shims on the 9. Install the strip bearings and the shims on the
channels of the outer mast weldment. See Fig- channels of the intermediate mast weldment.
ure 18. Apply chassis lube to the bearing sur- Apply chassis lube to the bearing surfaces.
faces. Check the clearance of the strip bearings Install the load rollers and the shims on the
as described in Carriage Adjustment. intermediate and inner mast weldments. Before
doing the next step, adjust the inner mast weld-
3. Install the load rollers and the shims on the ment as described in Carriage Adjustment.
outer mast weldment and at the bottom of the
intermediate mast weldment. Before doing the 10. Connect the main lift chains to the chain anchors
next step, adjust the intermediate mast weld- at the main lift cylinder mounts. Put the lift
ment and check the clearance of the load rollers chains over the chain sheaves and connect them
as described in Carriage Adjustment. to the anchors at the bottom of the inner mast
weldment.
NOTE: The clearance check and adjustment in Step 4
is only an initial setup. The final check and adjust- 11. Install the free-lift cylinder in the mounts on
ment is done after the mast is installed on the lift the inner mast weldment. Install the brackets
truck. for the cylinder and tighten the nuts to 38 N•m
(28 lbf ft). On the three-stage FFL mast, the
4. Install the main lift cylinders. Push the interme- nuts are installed on the bracket side of the
diate mast weldment to engage the lift cylinders. free-lift cylinder.
Check the clearance at the top of the lift cylin-
der mounts. Add or remove washers at the top of 12. Install the hose sheave for the free-lift cylinder.
the cylinder rods until they are even. Install the Tighten the capscrew for the hose sheave to
snap ring and washer at the top of the lift cylin- 66 N•m (49 lbf ft). Install the hydraulic hose
ders. and tubing for the free-lift cylinder.
5. Install the housing for the lowering control valve 13. Connect the free-lift chains to the chain anchors
on the outer mast weldment. Tighten the nuts for at the crossmember. Attach a wire between the
the lowering control valve to 18 N•m (13 lbf ft). end of the lift chain and the bottom of the mast
Install the lowering control valve in the housing. to control the lift chain during mast installation.
Connect the hydraulic lines and fittings between
the lowering control valve and the main lift cylin-
ders.
25
INSTALL the capscrews that hold the mast to the pivot

pins. Tighten the capscrews to 130 N•m
1. On the H/S2.00-3.20XM (H/S40-65XM), (96 lbf ft).
E2.00-3.20XM (E40-65XM, E40-65XM 2)
(F108), E2.00-3.20XM (E45-65Z) (G108), b. On the H/S1.50-1.75XM, H/S2.00XMS
J2.00-3.20XM (J40-60XM, J40-60XM 2) (A216), (H/S25-35XM, H/S40XMS), E1.50-1.75XM
and J2.00-3.20XM (J40-65Z) (A416), lubricate (E25-35XM, E25-35XM 2) (D114), E2.00XMS
the pivot pins with chassis lube and install them (40XMS, 40XM SS) (D114), E1.50-2.00XM
into the mounts at the drive axle hanger. On the (E25-35Z, E40ZS) (E114), S/E/J2.00-3.00XL
H/S1.50-1.75XM, H/S2.00XMS (H/S25-35XM, (S/E/J40-60XL), and J1.60-2.00XMT
H/S40XMS), E1.50-1.75XM (E25-35XM, (J30-40XMT), install the mast on the drive
E25-35XM 2) (D114), E2.00XMS (E40XMS, axle. Install the capscrews and bushings
E40XM 2S) (D114), E1.50-2.00XM (E25-35Z, that hold the retainer caps and mast assem-
E40ZS) (E114), J1.60-2.00XMT (J30-40XMT); bly to the drive axle. Tighten the capscrews
and S/E/J2.00-3.00XL (S/E/J40-60XL), lubri- to 90 N•m (66 lbf ft).
cate the bushings with chassis lube and install
them into the mounts on the mast. On the c. On the J1.60-2.00XMT (J30-40ZT), install
J1.60-2.00XMT (J30-40ZT) lubricate the bush- the mast into the transmission housing
ings with chassis lube and install them onto mounts. Apply HCE-92 adhesive sealant
the stub shafts at the bottom of the outer mast (Loctite ™ #290) to capscrew threads. In-
weldment. stall the capscrews, bushing, and retainer
caps. Tighten the capscrews to 34.8 N•m
(25.7 lbf ft).
WARNING
The mast is heavy. The mast can weigh approx- NOTE: Lubricate the anchor pins with chassis grease
imately 1600 kg (3527 lb). Make sure all lift- before installation.
ing devices (hoists, cables, chains, slings, etc.)
are suitable and of adequate capacity to lift the 4. Connect the tilt cylinders to the mast. Install
mast. the anchor pins and/or cotter pins, washers, or
capscrews.
CAUTION 5. Connect the hydraulic line to the lowering control
Make sure the chains will not damage the valve.
sheaves, tubing, or other parts of the mast.
6. Install the carriage as described in Carriages Re-
2. Connect a crane with a capacity of at least pair.
1600 kg (3527 lb) to the top of the mast using
chains. Make sure all the mast weldments are 7. Check the tilt cylinder adjustment as described
fastened together. Make sure the chains will not in Carriage Adjustment. Operate the mast and
damage the sheaves, tubing, or other parts of check for leaks and correct operation. Check the
the mast. lift chains as described in Carriage Adjustment.
3. Use the crane to install the mast assembly: NOTE: The load rollers and sheaves have sealed bear-
ings and do not need additional lubrication.
a. On the H/S2.00-3.20XM (H/S40-65XM),
E2.00-3.20XM (E40-65XM, E40-65XM 2) 8. Lubricate the sliding surfaces and the load roller
(F108), E2.00-3.20XM (E45-65Z) (G108), surfaces along the full length of the channels as
J2.00-3.20XM (J40-60XM, J40-60XM 2) shown in Figure 19. Apply chassis lube only to
(A216), and J2.00-3.20XM (J40-65Z) (A416), the surfaces indicated.
install the mast on the pivot pins. Install
26
4000 SRM 522 Lift Cylinders Repair

A. UPPER LOAD ROLLERS
B. LOWER LOAD ROLLERS
1. LUBRICATE STRIP BEARINGS SURFACES
WITH CHASSIS LUBE
2. LUBRICATE LOAD ROLLER SURFACES WITH
CHASSIS LUBE
3. LOAD ROLLER
Figure 19. Mast Lubrication
Lift Cylinders Repair

MAIN LIFT CYLINDERS, REMOVE 3. Remove the snap ring or fitting at the top of the
lift cylinder that needs to be removed.
WARNING
Before working on or near the mast, see Safety WARNING
Procedures When Working Near Mast in this Hydraulic oil is hot after system operation and
section. can cause burns. Do not disconnect any hy-
draulic hoses until the oil in the system is cool.
NOTE: The following procedures are for the removal
of the lift cylinders with the mast installed on the lift 4. Put a drain pan under the area of the hydraulic
truck. fittings. Disconnect the hydraulic line at the
cylinder. Retract the rod into the lift cylinder.
1. Remove the carriage as described in the proce-
dures for Carriages Repair. See Figure 13, Fig- 5. Remove the nut, bolt, and spacer at the mount.
ure 14, and Figure 16. Disconnect the main lift chain at the mount.
2. Raise the mast until it is almost fully extended. 6. Remove the lift cylinder from the front of the
Use safety chains to connect the bottom cross- mast. Use a lifting device as necessary.
member of the inner mast weldment (two-stage)
or intermediate mast weldment (three-stage) to FREE-LIFT CYLINDER, REMOVE
the top crossmember of the outer mast weldment.
On the three-stage mast, use a safety chain to 1. Remove the carriage as described in the proce-
connect the bottom crossmember to a crossmem- dures for Carriages Repair. Lower the mast com-
ber on the intermediate or outer mast weldment. pletely. See Figure 14 and Figure 16.
Lower the mast so the safety chains hold the
weight of the weldments. WARNING
WARNING can cause burns. Do not disconnect any hy-
Be careful when removing or installing snap draulic hoses until the oil in the system is cool.
rings. These snap rings can come loose dur-
2. Put a drain pan under the area of the hydraulic
ing removal or installation with enough force
fittings. Disconnect the hydraulic line at the
cylinder.
ring pliers, and wear eye and face protection
during removal or installation. 3. Remove the brackets for the free-lift cylinder. Re-
move the free-lift cylinder.
27
Lift Cylinders Repair 4000 SRM 522
4. Remove the crosshead from the cylinder rod. See completely disassembled. All of the lift cylinders are
Figure 20. Disassemble the crosshead as neces- disassembled from the rod end of the cylinder shell.
sary.
1. Loosen the retainer with a spanner wrench. Re-
move the retainer from the shell. See Figure 21,
Figure 22, Figure 23, and Figure 24.
2. Pull the rod and piston assembly from the shell.

Drain the hydraulic oil into a container.
3. Remove the retainer from the piston rod. Re-

move and discard the O-rings, seals, and wear
rings.
WARNING
rings. These snap rings can come loose dur-
ing removal or installation with enough force
ring pliers and wear eye and face protection
during removal or installation.
4. Remove the snap ring, washer, and check valve

from the base of the piston.
NOTE: THE SPACERS ARE ONLY INSTALLED
ON EARLIER H/S2.00-3.20XM (H/S40-65XM), 5. Clean all the parts. Check the sliding surfaces
E2.00-3.20XM (E40-65XM, E40-65XM 2) (F108), for damage. Repair or replace any damaged
J2.00-3.20XM (J40-60XM, J40-60XM 2) (A216), AND parts.
S/E/J2.00-3.00XL (S/E/J40-60XL), MODELS. MAKE
A NOTE OF THE NUMBER OF SPACERS IN EACH LIFT CYLINDERS, ASSEMBLE
LOCATION.
1. LIFT CHAIN 6. BEARING CAUTION
2. CHAIN SHEAVE 7. PIN
3. CHAIN GUARD 8. FREE-LIFT The correct screw and washer must be used
4. SNAP RING CYLINDER in this location. The wrong parts will cause
5. CROSSHEAD 9. SPACER leaks or damage the cylinder. See your HYS-
TER lift truck dealer for the correct parts. See
Figure 20. Crosshead Assembly, Two-Stage and Figure 21 and Figure 24.
Three-Stage FFL Mast
1. Lubricate all internal parts of the lift cylinder
LIFT CYLINDERS, DISASSEMBLE with clean hydraulic oil or packing lubricant,
Hyster Part No. 186061. Use new O-rings, seals,
and wear rings.
CAUTION
Carefully disassemble the lift cylinders so the 2. Install the check valve and O-ring in the base of
piston rods and sliding surfaces are not dam- the piston. Make sure the arrow on the check
aged. valve is toward the base of the piston. Install the
washer and snap ring for the check valve.
NOTE: Disassembly of the main lift cylinders and the
free-lift cylinder is similar, but all cylinders cannot be
28
A. RIGHT-HAND CYLINDER B. LEFT-HAND CYLINDER

1. SHELL 7. O-RING
2. ROD AND PISTON 8. WEAR RING
3. WIPER 9. PISTON RING
4. ROD SEAL 10. SCREW*
5. RETAINER 11. SEALING WASHER*
6. BACKUP RING 12. WEAR RING
*H/S2.00-3.20XM (H/S40-65XM), E2.00-3.20XM (E40-65XM, E40-65XM 2) (F108), E2.00-3.20XM (E45-65Z)

(G108), J2.00-3.00XM (J40-60XM, J40-60XM 2) (A216), J2.00-3.00XM (J40-65Z) (A416), AND S/E/J2.00-3.00XL
(S/E/J40-60XL),
Figure 21. Main Lift Cylinders, Two-Stage Full Free-Lift Mast
29
Lift Cylinders Repair 4000 SRM 522
1. SHELL 9. BACKUP RING

2. SNAP RING 10. ROD
3. WASHER 11. SPACER
4. O-RING 12. O-RING
5. CHECK VALVE 13. WEAR RING
6. PISTON RING 14. RETAINER
(THREE-STAGE 15. SEAL
FFL ONLY) 16. BACKUP RING
7. WEAR RING 17. WIPER
8. SEAL
Figure 22. Main Lift Cylinders, Two-Stage 1. WIPER 8. PISTON SEAL

2. ROD SEAT 9. WEAR RING
Limited Free-Lift and Three-Stage Full 3. RETAINER 10. CHECK VALVE
Free-Lift Mast for H/S1.50-1.75XM, H/S2.00XMS 4. O-RING 11. WASHER
(H/S25-35XM, H/S40XMS), E1.50-1.75XM 5. SPACER 12. SNAP RING
(E25-35XM, E25-35XM 2) (D114), E2.00XMS 6. ROD AND PISTON 13. SHELL
(E40XMS, E40XM 2S) (D114), and E1.50-2.00XM 7. BACKUP RING
(E25-35Z, E40ZS) (E114) Figure 23. Main Lift Cylinders, Two-Stage
Limited Free-Lift and Three-Stage Full
CAUTION Free-Lift Mast
A difficult and important step in assembling
4. Carefully push the piston and rod assembly into
lift cylinders is the correct installation of the
the shell.
seals. Most lift cylinder maintenance is caused
by seal leaks. Do not damage any parts during 5. Install the rod seal ring and wiper into the re-
assembly. tainer. Install the O-ring and backup ring on the
outside of the retainer.
3. Install the wear ring, piston seal, and backup
ring on to the piston assembly. If a spacer is used, 6. Carefully install the retainer on the piston rod.
install it.
30
9. Install the lowering control valve. See Figure 13,

Figure 14, and Figure 16. Make sure the special
washer and the spring are installed correctly. A
wrong installation can cause the load to lower too
fast.
MAIN LIFT CYLINDERS, INSTALL

1. Use a crane with a capacity of at least 1600 kg
(3527 lb) to raise the mast until it is almost fully
extended. Use safety chains to connect the bot-
tom crossmember of the inner mast weldment
(two-stage) or intermediate mast weldment
(three-stage) to the top crossmember of the outer
mast weldment. Lower the mast so the safety
chains hold the weight of the weldments. See
Figure 13, Figure 14, and Figure 16.
2. Install the lift cylinder in the mount at the bot-

tom of the outer mast weldment. Install the nut,
bolt, and spacer at the mount for the lift cylinder.
3. Use a lifting device to lower the inner mast weld-

ment (two-stage) or intermediate mast weldment
(three-stage) on to the lift cylinder. Install the
washers and snap ring at the top of the lift cylin-
der. See Two-Stage LFL and Two-Stage FFL
Mast, Assemble and Three-Stage FFL Mast,
Assemble procedures for the correct adjustment
of the lift cylinders.
4. Connect the hydraulic line at the base of the lift

cylinder. Connect the hydraulic line at the top of
the left-hand main lift cylinder on the full free-lift
mast.
1. WIPER 9. WEAR RING 5. Connect the main lift chains as necessary and
2. ROD SEAL 10. SCREW
3. RETAINER 11. SEALING WASHER adjust them as specified in Carriage Adjustment.
4. BACKUP RING 12. CHECK VALVE
5. O-RING 13. SHELL 6. Remove the air from the cylinders on the two-
6. ROD AND PISTON 14. WASHER stage FFL. See Figure 21.
7. BACKUP RING 15. SNAP RING
8. PISTON SEAL a. Loosen the screws two turns to permit oil to
flow around the threads of the screw.
Figure 24. Free-Lift Cylinder, Two-Stage Full
Free-Lift and Three-Stage Full Free-Lift Mast b. With the forks unloaded and the engine
speed at idle, raise the carriage using the hy-
7. Free-lift cylinder only. Remove screw and draulic control. Raise the carriage 300 mm
sealing washer. Pour 150 cc (5 oz) of hydraulic (12 in.) and then stop for ten seconds to
oil into the cylinder through the hole. This oil reduce the pressure in the cylinder. Repeat
provides a hydraulic cushion when the cylinder this procedure until the oil flowing from
reaches the top of its stroke. around the threads is free of air bubbles.
8. Engage the threads and turn the retainer in the c. Stop the carriage at the top of the cylinder
shell until it is tight. Use the correct spanner. Do stroke. Tighten the screws.
NOT hit the retainer with a hammer and driver.
31
Header Hose Arrangements 4000 SRM 522
FREE-LIFT CYLINDER, INSTALL (39 lbf ft). On the three-stage FFL mast, the nuts
are installed on the bracket side of the free-lift
1. Install the crosshead assembly on the cylinder cylinder. Tighten the nuts to 38 N•m (28 lbf ft).
rod. Tighten the capscrews for the chain guards
to 66 N•m (49 lbf ft). See Figure 14, Figure 16, 3. Connect the hydraulic line at the cylinder.
Figure 20, and Figure 24.
4. Install the carriage as described in the proce-
2. Install the cylinder in the mounts. Install dures for the Carriages Repair.
the brackets and tighten the bolts to 53 N•m
Header Hose Arrangements

NOTE: This is for H/S2.00-3.20XM (H/S40-65XM), 2. Use a calculator to calculate dimension E. See
E2.00-3.20XM (E40-65XM, E40-65XM 2) (F108), Figure 25.
E2.00-3.20XM (E45-65Z) (G108), J2.00-3.20XM
(J40-60XM, J40-60 2) (A216), J2.00-3.20XM (J40- 3. Clamp the end of the hose (the smaller fitting)
65Z) (A416), and S/E/J2.00-3.00XL (S/E/J40-60XL) that attaches to the carriage in a vise (do not
models. clamp on the threads), pull on the other end until
the hose is straight. Do not apply enough force to
NOTE: Hoses have a service life that is determined by stretch the hose. See Figure 25.
application and time. All hoses must be inspected at
the intervals specified in the Maintenance Schedule 4. Mark the hoses with dimension E [all measure-
for the hydraulic system. Install a new hose if the ments are made from the carriage end of the hose
hose is worn, damaged, soft or hard, and no longer (the smaller fitting)]. See Figure 25.
flexible. If necessary, make a comparison to a new
5. Attach the hoses to the carriage bracket with the
hose that is the correct replacement for the hose you
clamps. See Figure 26.
are inspecting.
6. Place the hoses at the location of the hose
Some lift trucks have auxiliary hydraulic equipment
sheave. The hose sheave and guard must be as-
that is attached to the carriage. Examples of aux-
sembled onto the hose before they are attached
iliary equipment are a sideshift carriage or a roll
to the mast. Tighten the mounting hardware to
clamp. These auxiliary functions require arrange-
66 N•m (49 lbf ft).
ments of header hoses for their operation.
7. Put the clamps over the hoses and attach the
TWO-STAGE LFL MAST, NEW HOSE clamps to the brackets. (Do NOT tighten the
INSTALL hardware.)
NOTE: To make the alignment of dimension E easier,

WARNING
use a crane with a capacity of at least 908 kg (2002 lb)
Before working on or near the mast, see Safety to raise the carriage high enough to install a safety
Procedures When Working Near Mast in this chain. See Figure 27 and Step 8 and Step 9.
section.
8. The following procedures must be used when in-
NOTE: This procedure is for the four-function option. stalling safety chains for the header hose instal-
The three-function option will have hoses A and B lation. Additional precautions and procedures
only. can be required when repairing or removing the
NOTE: The carriage height must be correct before the mast. See Safety Procedures When Working
header hoses can be adjusted. See Lift Chains Ad- Near Mast in this section for additional proce-
justment for the carriage adjustment procedure. dures for the installation of safety chains.
1. Mark each hose with a single letter: A, B, C, or

D.
32
4000 SRM 522 Header Hose Arrangements
Figure 25. Header Hose Measurement, Two-Stage Limited Free-Lift Mast
33
* Metric Formulas (All Dimensions are in Millimeters)

@ Dimension E = (0.985 × Z) + (0.985 × Y) + 244
# Dimension E = (0.985 × Z) + (0.985 × Y) + 220
% Dimension E = (0.985 × Z) + (0.985 × Y) + 283
Example: Dimension E = (0.985 × Z) + (0.985 × Y) + 244
Step 1. Dimension E = (0.985 × 135) + (0.985 × 2290) + 244
Step 2. Dimension E = 133 + 2255.7 + 244
Step 3. Dimension E = 2388.7 + 244
Step 4. Dimension E = 2633
* Inch Formulas (All Dimensions are in Inches)

@ Dimension E = (0.985 × Z) + (0.985 × Y) + 9.6
# Dimension E = (0.985 × Z) + (0.985 × Y) + 8.7
% Dimension E = (0.985 × Z) + (0.985 × Y) + 11.1
Example: Dimension E = (0.985 × Z) + (0.985 × Y) + 9.6
Step 1. Dimension E = (0.985 × 5.3) + (0.985 × 90.0) + 9.6
Step 2. Dimension E = 5.2 + 88.7 + 9.6
Step 3. Dimension E = 93.9 + 9.6
Step 4. Dimension E = 103.5
*All measurements are made with mast vertical and fully lowered.
@H2.00-2.50XM (H40-50XM)
#H3.00-3.20XM (H60-65XM), J2.00-3.00XL (J40-60XL)
%E2.00-3.20XM (E40-65XM, E40-65XM 2) (F108), E2.00-3.20XM (E45-65Z) (G108), and S/E2.00-3.00XL
(S/E40-60XL)
1. DIMENSION E 4. TOP OUTER CHANNEL

2. HOSE 5. BOTTOM OUTER CHANNEL
3. VISE 6. GROUND LEVEL
34
Figure 26. Header Hoses, Two-Stage Limited Free-Lift Mast
35

A. ALIGN MARK E AT BOTTOM OF THIS CLAMP
1. SPECIAL WASHER 7. COWL HOSES
2. HOSE SHEAVE 8. BOTTOM CLAMP
3. HOSE GUARD 9. HEADER HOSES
4. WASHER 10. BRACKET, UPPER
5. CAPSCREW 11. BRACKET, CARRIAGE
6. CLAMP (TOP OF LIFT CYLINDER) 12. CLAMPS
1. HOOK 2. SHACKLE
Figure 27. Safety Chain Installation, Two-Stage Limited Free-Lift Mast
36
the top crossmembers. Make sure the hook is

WARNING completely engaged with a link in the chain.
Mast parts are heavy and can move. Distances
between parts are small. Serious injury or d. Attach a shackle to the lifting eye on the car-
death can result if part of the body is hit by riage. Install the chain through the shackle.
parts of the mast or the carriage. Make sure the hook is completely engaged
• Never put any part of the body into or under with a link in the chain. Make sure the
the mast or carriage unless all parts are com- safety chain does not touch lift chains, chain
pletely lowered or a safety chain is installed. sheaves, tubes, hoses, fittings, or other parts
Also make sure that the power is off, the key of the mast.
is removed, and the parking brake is applied.
• Put a DO NOT OPERATE tag in the operator’s e. Lower the crane until there is tension in the
compartment. safety chain. Make sure both hooks are prop-
• Be careful of the forks. When the mast is erly engaged before working on the mast. In-
raised, the forks can be at a height to cause stall a DO NOT REMOVE tag on the safety
an injury. chain.
• DO NOT climb on the mast or lift truck at any 10. Align mark E at the bottom of the clamp. Tighten
time. Use a ladder or personnel lift to work the hardware to 8 N•m (71 lbf in).
on the mast.
• DO NOT use blocks to support the mast weld- 11. Connect the header hoses to the cowl hoses.
ments nor to restrain their movement.
• Mast repairs require disassembly and re- 12. Use the rubber clamps and strap clamps to at-
moval of parts and can require removal of tach the hoses to the main lift cylinders. Make
the mast or carriage. Follow the repair pro- sure the cowl hoses do not stretch or fold while
cedures in the correct Service Manual for tilting the mast fully forward and backward.
the mast.
13. With no load on the forks, check the header hose
9. SAFETY CHAIN INSTALLATION WHEN adjustment by operating the mast through the
THE CARRIAGE IS RAISED: full lift cycle two times. When properly adjusted,
the hoses will not be so tight that they compress
a. Put the mast in a vertical position. when they pass over the sheaves nor will they
be so loose that they touch the load backrest or
b. Raise the carriage approximately 300 mm any crossmember that is next to a sheave. If the
(12 in.). hoses require additional adjustment, see Two-
c. Use a 3/8 inch minimum safety chain with a Stage LFL Mast, Adjust Hoses After Installation.
hook. Attach one end of the chain around all
37
TWO-STAGE LFL MAST, ADJUST HOSES 4. Mark the hoses with dimension E [all measure-
AFTER INSTALLATION ments are made from the carriage end of the hose
(the smaller fitting)]. See Figure 28.
1. Loosen the clamps and pull (if the hoses are
loose) or push (if the hoses are tight) on the 5. Attach the hoses to the carriage bracket with
hoses so that they move 30 mm (1.2 in.). Tighten clamp. See Figure 29.
the hardware to 8 N•m (71 lbf in). See Figure 25,
6. Put the header hoses over the free-lift chains.
Figure 26, and Figure 27.
clamps to the lower bracket (do NOT tighten the
adjustment by operating the mast through the
hardware).
full lift cycle two times. When properly adjusted,
the hoses will not be so tight that they compress NOTE: To make the alignment of dimension E easier,
when they pass over the sheaves nor will they be use a crane with a capacity of at least 908 kg (2002 lb)
so loose that they touch the load backrest or any to raise the carriage high enough to install a safety
crossmember that is next to a sheave. If neces- chain.
sary, repeat Step 1 until the hoses are properly
adjusted. 8. Align mark E at the bottom of the clamp. Tighten
the hardware to 8 N•m (71 lbf in).
TWO-STAGE FFL MAST, NEW HOSE
INSTALL 9. Install the hose guards at the free-lift crosshead.
Tighten the capscrews that mount the guards to
66 N•m (49 lbf ft).
WARNING
Before working on or near the mast, see Safety NOTE: The proper hose alignment is shown in Fig-
Procedures When Working Near Mast in this ure 30.
section.
10. Apply a spray lubricant onto the hoses in the area
NOTE: This procedure is for the four-function option. that will contact the channels. Make sure the
The three-function option will have hoses A and B hoses are properly aligned in the channels. Put
only. the clamps over the hoses and attach the clamps
to the channels. Tighten the hardware to 8 N•m
NOTE: The carriage height must be correct before the (71 lbf in). See Figure 30.
header hoses can be adjusted. See Lift Chains Ad-
justment for the carriage adjustment procedure. 11. Connect the header hoses (10, C, and D) to the
cowl hoses. Connect the header hoses (10, A, and
1. Mark each hose with a single letter: A, B, C, or B) to the tubes.
D.
12. Use the rubber clamps and strap clamps to at-
2. Use a calculator to calculate dimension E. See tach the hoses to the main lift cylinders. Make
Figure 28. sure the cowl hoses do not stretch or fold while
tilting the mast fully forward and backward.
3. Clamp the end of the hose (the smaller fitting)
that attaches to the carriage in a vise (do NOT
clamp on the threads), pull on the other end until
the hose is straight. Do NOT apply enough force
to stretch the hose. See Figure 28.
38
Figure 28. Header Hose Measurement, Two-Stage Full Free-Lift Mast
39

Class II Mast Type
Dimension E = (0.492 × Y) + (0.985 × Z) + 303
Example: Dimension E = (0.492 × Y) + (0.985 × Z) + 303
Step 1. Dimension E = (0.492 × 2482) + (0.985 × 2095) + 303
Step 2. Dimension E = 1221.1 + 2063.6 + 303
Dimension G Calculations are Similar to Dimension E
Dimension G (3 Function) for Lift Heights of 2482 mm to 2982 mm:
(1.982 × Y) + (0.985 × Z) 801
(1.991 × Y) + (0.985 × Z) 917
(1.982 × Y) + (0.985 × Z) 868
(1.991 × Y) + (0.985 × Z) 1046

Class II Mast Type
Dimension E = (0.492 × Y) + (0.985 × Z) + 11.938
Example: Dimension E = (0.492 × Y) + (0.985 × Z) + 11.938
Step 1. Dimension E = (0.492 × 97.7) + (0.985 × 82.5) + 11.938
Step 2. Dimension E = 48.1 + 81.3 + 11.938
Step 3. Dimension E = 129.4 + 11.938
Dimension G (3 Function) for Lift Heights of 97.7 to 117.4
(1.982 × Y) + (0.985 × Z) 31.531
(1.991 × Y) + (0.985 × Z) 36.125
(1.982 × Y) + (0.985 × Z) 34.156
(1.991 × Y) + (0.985 × Z) 41.156
40
Legend for Figure 28 (Continued)

Class III Mast Type
Dimension E = (0.492 × Y) + (0.985 × Z) + 269
The Calculation for Dimension E for Class III Mast is the Same as Class II Mast. See Class
II Mast - Metric Formula.
(1.981 × Y) + (0.985 × Z) 851
(1.991 × Y) + (0.985 × Z) 972
(1.981 × Y) + (0.985 × Z) 919
(1.991 × Y) + (0.985 × Z) 1100

Class III Mast Type
Dimension E = (0.492 × Y) + (0.985 × Z) + 10.594
The Calculation for Dimension E for Class III Mast is the Same as Class II Mast. See Class II
Mast - Inch Formula.
(1.981 × Y) + (0.985 × Z) 33.500
(1.991 × Y) + (0.985 × Z) 38.281
(1.981 × Y) + (0.985 × Z) 36.156
(1.991 × Y) + (0.985 × Z) 43.312
1. DIMENSION G 5. HOSE
2. DIMENSION E 6. BOTTOM OUTER CHANNEL
4. TOP OUTER CHANNEL
41
Figure 29. Header Hoses, Two-Stage Full Free-Lift Mast
42
NOTE: FOUR-FUNCTION MAST SHOWN.

A. ALIGN MARK E AT BOTTOM OF THIS CLAMP
1. HOSE CHANNEL 14. CARRIAGE BRACKET
2. COWL HOSES 15. BOTTOM CLAMP
3. HEADER HOSES 16. HOSE GUIDE
4. STRAP CLAMP 17. SNAP RING
5. CLAMP 18. CAPSCREW (THREE-FUNCTION)
6. CLAMP 19. CAPSCREW (FOUR-FUNCTION)
7. FITTING 20. HOSE GUARD
8. TUBE 21. STUBSHAFT
9. FITTING 22. SHEAVE
10. CLAMP 23. WASHER
11. BRACKET 24. WASHER
12. LOWER BRACKET 25. NUT
13. CAPSCREW
13. With no load on the forks, operate the mast TWO-STAGE FFL MAST, ADJUST HOSES
through the full lift cycle two times. With the AFTER INSTALLATION
mast at full lift height, attach clamp at the bot-
tom of the hose loop on the third and/or fourth 1. Loosen the clamps and pull (if the hoses are
function hoses. This action allows the hoses to loose) or push (if the hoses are tight) on the
fit properly in the hose channel. hoses so that they move 15 mm (0.6 in.). Tighten
the hardware to 8 N•m (71 lbf in). See Figure 28,
14. With no load on the forks, check the header hose Figure 29, Figure 30, and Figure 34.
full lift cycle two times. When properly adjusted, 2. With no load on the forks, check the header hose
the hoses will not be so tight that they compress adjustment by operating the mast through the
when they pass over the sheaves nor will they full lift cycle two times. When properly adjusted,
be so loose that they touch the load backrest or the hoses will not be so tight that they compress
any crossmember that is next to a sheave. If the when they pass over the sheaves nor will they be
hoses require additional adjustment, see Two- so loose that they touch the load backrest or any
Stage FFL Mast, Adjust Hoses After Installation. crossmember that is next to a sheave. If neces-
adjusted.
43
Figure 30. Header Hose Alignment, Two-Stage Full Free-Lift Mast
44
THREE-STAGE FFL MAST, NEW HOSE Working Near Mast in this section for additional
INSTALL procedures for installation of safety chains.
WARNING WARNING
Before working on or near the mast, see Safety Mast parts are heavy and can move. Distances
Procedures When Working Near Mast in this between parts are small. Serious injury or
section. death can result if part of the body is hit by
parts of the mast or the carriage.
NOTE: This procedure is for the four-function option. • Never put any part of the body into or under
The three-function option will have hoses A and B the mast or carriage unless all parts are com-
only. pletely lowered or a safety chain is installed.
Also make sure that the power is off, the key
NOTE: The carriage height must be correct before the
is removed, and the parking brake is applied.
header hoses can be adjusted. See Lift Chains Ad-
Put a DO NOT OPERATE tag in the operator’s
justment for the carriage adjustment procedure.
compartment.
1. Mark each hose with a single letter: A, B, C, or • Be careful of the forks. When the mast is
D. raised, the forks can be at a height to cause
an injury.
2. Use a calculator to calculate the dimensions E • DO NOT climb on the mast or lift truck at any
and G. See Figure 31. time. Use a ladder or personnel lift to work
on the mast.
3. Clamp the end of the hose (the smaller fitting) • DO NOT use blocks to support the mast weld-
that attaches to the carriage in a vise (do NOT ments nor to restrain their movement.
clamp on the threads), pull on the other end until • Mast repairs require disassembly and re-
the hose is straight. Do NOT apply enough force moval of parts and can require removal of
to stretch the hose. See Figure 31. the mast or carriage. Follow the repair pro-
cedures in the correct Service Manual for
4. Mark all the hoses with dimensions E and G (all
the mast.
measurements are made from the carriage end of
the hose [the smaller fitting]). See Figure 31. 8. SAFETY CHAIN INSTALLATION WHEN
THE CARRIAGE IS RAISED:
5. Attach the hoses to the carriage bracket with
clamp. Apply grease to the surface of the hose a. Put the mast in a vertical position.
guide that contacts the hoses. See Figure 32.
b. Raise the carriage approximately 300 mm
NOTE: The hoses cross each other in two locations. (12 in.).
The proper hose alignment is shown in Figure 33.
c. Use a 3/8 inch minimum safety chain with a
6. Place the hoses over the top of the free-lift chains hook. Attach one end of the chain around all
and under the hose guides. See Figure 32 and the top crossmembers. Make sure the hook is
Figure 33. Put the clamps over the hoses and completely engaged with a link in the chain.
attach the clamps to the lower bracket (do NOT
tighten the hardware). d. Attach a shackle to the lifting eye on the car-
riage. Install the chain through the shackle.
NOTE: To make the alignment of dimension E easier, Make sure the hook is completely engaged
use a crane with a capacity of at least 908 kg (2002 lb) with a link in the chain. Make sure the
to raise the carriage high enough to attach a safety safety chain does not touch lift chains, chain
chain. See Figure 34 and Step 7, Step 8, and Step 9. sheaves, tubes, hoses, fittings, or other parts
of the mast.
7. The following procedures MUST be used when
installing safety chains for the header hose e. Lower the crane until there is tension in the
installation. Additional precautions and pro- safety chain. Make sure both hooks are prop-
cedures can be required when repairing or re- erly engaged before working on the mast. In-
moving the mast. See Safety Procedures When stall a DO NOT REMOVE tag on the safety
chain.
45
Figure 31. Header Hose Measurement, Three-Stage Full Free-Lift Mast
46

Class II Mast Types
Dimension E = (0.985 × Y) + (0.985 × Z) 350**
Example: Dimension E = (0.985 × Y) + (0.985 × Z) 350
Step 1. Dimension E = (0.985 × 3710) + (0.985 × 2095) 350
Step 2. Dimension E = 3654.4 + 2063.6 350
Step 3. Dimension E = 5718 350
** For Lift Heights of 3710 mm to 6110 mm. For Lift Heights of 6260 mm to 8510 mm, Use 842
Dimension G for Lift Heights of 3710 mm to 6110 mm:
(1.965 × Y) + (0.985 × Z) 65
(1.965 × Y) + (0.985 × Z) 65

Class II Mast Types
Dimension E = (0.985 × Y) + (0.985 × Z) 8.781**
Example: Dimension E = (0.985 × Y) + (0.985 × Z) 8.781
Step 1. Dimension E = (0.985 × 146.1) + (0.985 × 82.5) 8.781
Step 2. Dimension E = 143.91 + 81.3 8.781
Step 3. Dimension E = 225.20 8.781
** For Lift Heights of 146.1 to 240.6. For Lift Heights of 246.5 To 335.0, Use 33.156
Dimension G for Lift Heights of 146.1 to 240.6
(1.965 × Y) + (0.985 × Z) 2.562
(1.965 × Y) + (0.985 × Z) 2.562
47

Class III Mast Type
Dimension E = (0.985 × Y) + (0.985 × Z) 350**
(1.965 × Y) + (0.985 × Z) 65
(1.965 × Y) + (0.985 × Z) 65

Class III Mast Type
Dimension E = (0.985 × Y) + (0.985 × Z) 8.781**
(1.965 × Y) + (0.985 × Z) 2.562
(1.965 × Y) + (0.985 × Z) 2.562
** For Lift Heights of 138.8 to 233.0. For Lift Heights of 238.9 to 327.5, Use 33.156
1. DIMENSION G 5. TOP OUTER CHANNEL

4. HOSE
48
Figure 32. Header Hoses, Three-Stage Full Free-List Mast
49
NOTE: THREE-FUNCTION MAST SHOWN.

1. CAPSCREW 13. LOWER HOSE GUIDE
2. HOSE GUARD 14. NUT
3. SNAP RING 15. BOTTOM CLAMP
4. HOSE GUIDE 16. HEADER HOSES
5. FREE-LIFT CYLINDER CROSSHEAD 17. FREE-LIFT CHAIN
6. WASHER 18. CLAMP
7. SPACER 19. COWL HOSES
8. HOSE SHEAVE 20. UPPER BRACKET
9. HOSE GUARD 21. CARRIAGE BRACKET
10. CLAMP 22. CLAMP
11. LOWER BRACKET 23. STUBSHAFT
12. HOSE RESTRAINT
9. SAFETY CHAIN INSTALLATION WHEN are attached to the mast. Tighten the hardware
THE INNER CHANNEL IS RAISED: to 53 N•m (39 lbf ft).
a. Put the mast in a vertical position. 12. Put the clamps over the hoses and attach the
clamps to the upper brackets. Do NOT tighten
b. The mast must be full lowered. the hardware.
c. Attach a crane to the top crossmember of the NOTE: To make the alignment of dimension G easier,
inner channel. Raise the inner channel ap- use a crane with a capacity of at least 908 kg (2002 lb)
proximately 600 mm (24 in.). to raise the inner channel high enough to install a
safety chain as shown in Figure 34.
d. Use a 3/8 inch minimum safety chain with a
hook. Attach one end of the chain around the 13. Align mark G on hoses A and D at the bottom
top crossmember of the outer channel. Make edge of clamp to create the proper tension. Align
sure the hook is completely engaged with a mark G on hoses B and C at the top edge of clamp
link in the chain. to create the proper tension. Tighten the hard-
ware to 8 N•m (71 lbf in).
e. Attach the other end of the chain around
the lower crossmember of the inner channel. 14. Install the hose restraints.
Make sure the hook is completely engaged
with a link in the chain. 15. Connect the header hoses to the cowl hoses.
f. Lower the crane until there is tension in the 16. Use the rubber clamps and strap clamps to at-
safety chain. Make sure both hooks are prop- tach the hoses to the main lift cylinders. Make
erly engaged before working on the mast. In- sure the hoses do NOT stretch or fold while tilt-
stall a DO NOT REMOVE tag on the safety ing the mast fully forward and backward.
chain.
10. Align the mark for dimension E at the bottom adjustment by operating the mast through the
of the clamp to create the proper hose tension. full lift cycle two times. When properly adjusted,
Tighten the hardware to 8 N•m (71 lbf in). In- the hoses will not be so tight that they compress
stall the hose guards. Tighten the capscrews that when they pass over the sheaves nor will they
mount the guards to 66 N•m (49 lbf ft). be so loose that they touch the load backrest or
any crossmember that is next to a sheave. If the
11. Position the hoses at the hose sheave. See Fig- hoses require additional adjustment, see Three-
ure 32 and Figure 33. The hose sheave and hose Stage FFL Mast, Adjust Hoses After Installation.
guard must be installed on to the hose before they
50
Figure 33. Header Hose Alignment, Three-Stage Full Free-Lift Mast (Sheet 1 of 3)
51
52
A. HOSE A F. FORKS
B. HOSE B G. FRONT VIEW
C. HOSE C H. LEFT-HAND CYLINDER
D. HOSE D I. ALIGN MARK E AT BOTTOM OF THIS CLAMP.
E. ALIGN MARK G ON HOSES A AND D AT J. REAR VIEW
BOTTOM OF THIS CLAMP. ALIGN MARK G ON K. RIGHT-HAND CYLINDER
HOSES B AND C AT BOTTOM OF THIS CLAMP.
1. FREE-LIFT SHEAVE 6. BOTTOM CROSSMEMBER, INNER CHANNEL
2. HOSE 7. RETAINER
3. HOSE GUIDE 8. FREE-LIFT CYLINDER
4. HOSE GUIDE 9. CYLINDER GUARD
5. HOSE
53
Figure 34. Safety Chain Installation, Two-Stage Full Free-Lift and Three-Stage
Full Free-Lift Mast (Sheet 1 of 2)
54
1. HOOK 2. SHACKLE
Figure 34. Safety Chain Installation, Two-Stage Full Free-Lift and Three-Stage
Full Free-Lift Mast (Sheet 2 of 2)
THREE-STAGE FFL MAST, ADJUST (if the hoses are too loose) or push (if the hoses
HOSES AFTER INSTALLATION are too tight) on the hoses so that they move
15 mm (0.6 in.) plus the amount the hoses were
1. If the tension of the hoses is correct between the moved in Step 1. Tighten the hardware to 8 N•m
carriage and the clamp at the lower bracket, go (71 lbf in).
to Step 2. If the tension of the hoses is not cor-
rect, loosen the clamps and pull (if the hoses are 3. With no load on the forks, check the header hose
loose) or push (if the hoses are tight) on the hoses adjustment by operating the mast through the
so that they move 15 mm (0.6 in.). Tighten the full lift cycle two times. When properly adjusted,
hardware to 8 N•m (71 lbf in). See Figure 30, the hoses will not be so tight that they compress
Figure 31, Figure 32, and Figure 33. when they pass over the sheaves nor will they be
so loose that they touch the load backrest or any
2. If the tension of the hoses is correct between the crossmember that is next to a sheave. If neces-
clamp at the upper bracket and the clamp at the sary, repeat Step 1 and Step 2 until the hoses are
lower bracket, go to Step 3. If the tension of the properly adjusted.
hoses is not correct, loosen the clamps and pull
55
Header Hose Arrangement 4000 SRM 522
Header Hose Arrangement

NOTE: This is the Header Hose Arrangement 4. Mark all the hoses with dimension E (all mea-
for H/S1.50-1.75XM, H/S2.00XMS (H/S25-35XM, surements are made from the carriage end of the
H/S40XMS), E1.50-1.75XM (E25-35XM, E25- hose [the smaller fitting]). See Figure 35.
35XM 2) (D114), E2.00XMS (E40XMS, E40XM 2S)
(D114), E1.50-2.00XM (E25-35Z, E40ZS) (E114), 5. Attach the hoses to the carriage brackets with
J1.60-2.00XMT (J30-40XMT), and J1.60-2.00XMT the clamps. See Figure 36.
(J30-40ZT) models.
6. Place the hoses at the location of the hose sheave.
NOTE: Hoses have a service life that is determined by The hose sheave and stub shaft must be assem-
application and time. All hoses must be inspected at bled on to the hose before they are attached to
the intervals specified in the Maintenance Sched- the mast. Tighten the mounting hardware to
ule for the hydraulic system. Install a new hose if the 66 N•m (49 lbf ft).
hose is worn, damaged, soft or hard, and no longer
flexible. If necessary, make a comparison to a new
clamps to the upper brackets. Do NOT tighten
hose that is the correct replacement for the hose you
the hardware.
are inspecting.
NOTE: To make the alignment of dimension E easier,
Some lift trucks have auxiliary hydraulic equipment
use a crane with a capacity of at least 908 kg (2002 lb)
that is attached to the carriage. Examples of aux-
to raise the carriage high enough to install a safety
iliary equipment are a sideshift carriage or a roll
chain as shown in Figure 27.
clamp. These auxiliary functions require arrange-
ments of header hoses for their operation. 8. Align mark E at the bottom of the clamps.
Tighten the hardware to 8 N•m (71 lbf in).
TWO-STAGE LFL MAST, NEW HOSE
INSTALL 9. Connect the header hoses to the cowl hoses.
10. Use the rubber clamps and hose clamps to attach

WARNING the hoses to the main lift cylinders. Make sure
Before working on or near the mast, see Safety the hoses do NOT stretch or fold while tilting the
Procedures When Working Near Mast in this mast fully forward and backward.
section.
NOTE: This procedure is for the four-function option. adjustment by operating the mast through the
The three-function option will have hoses A and B full lift cycle two times. When properly adjusted,
only. the hoses will not be so tight that they compress
when they pass over the sheaves nor will they
NOTE: The carriage height must be correct before the be so loose that they touch the load backrest or
header hoses can be adjusted. See Lift Chains Ad- any crossmember that is next to a sheave. If the
justment for the carriage adjustment procedure. hoses require additional adjustment, see Two-
1. Mark each hose with a single letter: A, B, C, or Stage LFL Mast, Adjust Hoses After Installation.
D. See Figure 27, Figure 35, and Figure 36.
TWO-STAGE LFL MAST, ADJUST HOSES
2. Use a calculator to calculate dimension E. See AFTER INSTALLATION
Figure 35.
1. Loosen the clamps and pull (if the hoses are
3. Clamp the end of the hose (the smaller fitting) loose) or push (if the hoses are tight) on the
that attaches to the carriage in a vise (do NOT hoses so they move 30 mm (1.2 in.). Tighten the
clamp on the threads), and pull on the other end hardware to 8 N•m (71 lbf in). See Figure 27,
until the hose is straight. Do NOT apply enough Figure 35, and Figure 36.
force to stretch the hose. See Figure 35.
56
4000 SRM 522 Header Hose Arrangement
2. With no load on the forks, check the header hose so loose that they touch the load backrest or any
adjustment by operating the mast through the crossmember that is next to a sheave. If neces-
full lift cycle two times. When properly adjusted, sary, repeat Step 1 until the hoses are properly
the hoses will not be so tight that they compress adjusted.
when they pass over the sheaves nor will they be
Figure 35. Header Hose Measurement, Two-Stage Limited Free-Lift Mast
57

Dimension E = (Y + Z + 204) × 0.98
Example: Dimension E = (Y + Z + 204) × 0.98
Step 1. Dimension E = (1840 + 135 + 204) × 0.98
Step 2. Dimension E = 2179 × 0.98
Step 3. Dimension E = 2135

Dimension E = (Y + Z + 8.0) × 0.98
Example: Dimension E = (Y + Z + 8.0) × 0.98
Step 1. Dimension E = (72.4 + 5.3 + 8.0) × 0.98
Step 2. Dimension E = 85.7 × 0.98
1. DIMENSION E 4. TOP OUTER CHANNEL

2. HOSE 5. BOTTOM OUTER CHANNEL
58
Figure 36. Header Hoses, Two-Stage Limited Free-Lift Mast
59

A. ALIGN MARK E AT BOTTOM OF THIS CLAMP. B. OLD STYLE
1. HOSES, HEADER 12. NUT
2. CLAMP, STRAP 13. CAPSCREW
3. FITTINGS 14. CLAMP
4. CAPSCREW 15. WASHER
5. BRACKET, CARRIAGE 16. CAPSCREW
6. SPACER 17. CAPSCREW
7. NUT 18. CLAMP
8. BRACKET, UPPER 19. CLAMP
9. STUBSHAFT 20. HOSE, COWL
10. SHEAVE 21. CLAMP
11. WASHER
TWO-STAGE FFL MAST, NEW HOSE clamp on the threads), and pull on the other end
INSTALL until the hose is straight. Do NOT apply enough
force to stretch the hose. See Figure 37.
WARNING 4. Mark all the hoses with dimension E (all mea-
Before working on or near the mast, see Safety surements are made from the carriage end of the
Procedures When Working Near Mast in this hose [the smaller fitting]). See Figure 37.
section.
5. Attach the hoses to the carriage bracket with
NOTE: This procedure is for the four-function option. clamps. See Figure 38.
The three-function option will have hoses A and B
only. 6. Put the header hoses over the free-lift chains.
NOTE: The carriage height must be correct before the 7. Put the clamps over the header hoses and at-
header hoses can be adjusted. See Lift Chains Ad- tach the clamps to the free-lift bracket. (DO NOT
justment for the carriage adjustment procedure. tighten the hardware.)
1. Mark each hose with a single letter: A, B, C, NOTE: To make the alignment of dimension E easier,
or D. See Figure 34, Figure 37, Figure 38, and use a crane with a capacity at least 908 kg (2002 lb)
Figure 39. to raise the carriage high enough to install a safety
2. Use a calculator to calculate dimension E. See
Figure 37. 8. Align mark E at the bottom of the clamp. Tighten
the hardware to 8 N•m (71 lbf in).
3. Clamp the end of the hose (the smaller fitting)
that attaches to the carriage in a vise (do NOT
60
Figure 37. Header Hose Measurement, Two-Stage Full Free-Lift Mast
61

Class II Mast Type
Dimension E = (0.492 × Y) + (0.985 × Z) + 303
Example: Dimension E = (0.492 × Y) + (0.985 × Z) + 303
Step 1. Dimension E = (0.492 × 2482) + (0.985 × 2095) + 303
Step 2. Dimension E = 1221.1 + 2063.6 + 303
(1.982 × Y) + (0.985 × Z) 801
(1.991 × Y) + (0.985 × Z) 917
Dimension G (4 Function) for Lift Heights of 2482 mm to 2982 mm
(1.982 × Y) + (0.985 × Z) 868
(1.991 × Y) + (0.985 × Z) 1046

Class II Mast Type
Dimension E = (0.492 × Y) + (0.985 × Z) + 11.938
Example: Dimension E = (0.492 × Y) + (0.985 × Z) + 11.938
Step 1. Dimension E = (0.492 × 97.7) + (0.985 × 82.5) + 11.938
Step 2. Dimension E = 48.1 + 81.3 + 11.938
Step 3. Dimension E = 129.4 + 11.938
Dimension G (3 Function) for Lift Heights of 97.7 to 117.4:
(1.982 × Y) + (0.985 × Z) 31.531
(1.991 × Y) + (0.985 × Z) 36.125
(1.982 × Y) + (0.985 × Z) 34.156
(1.991 × Y) + (0.985 × Z) 41.156
62

Class III Mast Type
Dimension E = (0.492 × Y) + (0.985 × Z) + 269
The Calculation For Dimension E For Class III Mast Is The Same As Class II Mast. See Class
Dimension G Calculations Are Similar to Dimension E
(1.981 × Y) + (0.985 × Z) 851
Dimension G (3 Function) for Lift Heights of 3060mm to 5360 mm:
(1.991 × Y) + (0.985 × Z) 972
Dimension G (4 Function) for Lift Heights of 2360 mm to 2960 mm
(1.981 × Y) + (0.985 × Z) 919
(1.991 × Y) + (0.985 × Z) 1100

Class III Mast Type
Dimension E = (0.492 × Y) + (0.985 × Z) + 10.594
(1.981 × Y) + (0.985 × Z) 33.500
(1.991 × Y) + (0.985 × Z) 38.281
(1.981 × Y) + (0.985 × Z) 36.156
(1.991 × Y) + (0.985 × Z) 41.156
1. DIMENSION G 5. HOSE
4. TOP OUTER CHANNEL
63
Figure 38. Header Hoses, Two-Stage Full Free-Lift Mast
64

A. ALIGN MARK E AT BOTTOM OF THIS CLAMP. B. OLD STYLE
1. CHANNEL 14. CARRIAGE BRACKET
2. COWEL HOSES 15. LOWER CLAMP
3. HEADER HOSES 16. HOSE GUIDE
4. STRAP CLAMP 17. SNAP RING
5. CLAMP 18. CLIP
6. CLAMP 19. CAPSCREW
7. FITTING 20. HOSE GUARD
8. TUBE 21. STUBSHAFT
9. FITTING 22. FITTING
10. CLAMP 23. SPACER
11. BRACKET 24. WASHER
12. FREE-LIFT BRACKET 25. NUT
13. FREE-LIFT CHAIN
NOTE: The proper hose alignment is shown in Fig- full lift cycle two times. When properly adjusted,
ure 39. the hoses will not be so tight that they compress
when they pass over the sheaves nor will they
9. Apply a spray lubricant on the hoses in the area be so loose that they touch the load backrest or
that will contact the channels. Make sure the any crossmember that is next to a sheave. If the
hoses are properly aligned in the channels. Put hoses require additional adjustment, see Two-
the clamps over the hoses and attach the clamps Stage FFL Mast, Adjust Hoses After Installation.
to the channels. Tighten the hardware to 8 N•m
(71 lbf in). See Figure 38. TWO-STAGE FFL MAST, ADJUST HOSES
10. Connect the header hoses (4, C, and D) to the AFTER INSTALLATION
cowl hoses. Connect the header hoses (4, A, and 1. Loosen the clamps and pull (if the hoses are
B) to the tubes. loose) or push (if the hoses are tight) on the
11. Use the rubber clamps and strap clamps to at- hoses so they move 15 mm (0.6 in.). Tighten the
tach the hoses to the main lift cylinders. Make hardware to 8 N•m (71 lbf in). See Figure 34,
sure the cowl hoses do NOT stretch or fold while Figure 37, Figure 38, and Figure 39.
tilting the mast fully forward and backward. 2. With no load on the forks, check the header hose
12. With no load on the forks, operate the mast adjustment by operating the mast through the
through the full lift cycle two times. With the full lift cycle two times. When properly adjusted,
mast at full lift height, attach clamp at the bot- the hoses will not be so tight that they compress
tom of the hose loop on the third and/or fourth when they pass over the sheaves nor will they be
function hoses. This action allows the hoses to so loose that they touch the load backrest or any
fit properly in the hose channel. crossmember that is next to a sheave. If neces-
13. With no load on the forks, check the header hose adjusted.
65
Figure 39. Header Hose Alignment, Two-Stage Full Free-Lift Mast
66
THREE-STAGE FFL MAST, NEW HOSE NOTE: To make the alignment of dimension E easier,
INSTALL use a crane with a capacity of at least 908 kg (2002 lb)
to raise the carriage high enough to attach a safety
WARNING
Before working on or near the mast, see Safety 7. Align the mark for dimension E at the bottom
Procedures When Working Near Mast in this of the clamp to create the proper hose tension.
section. Tighten the hardware to 8 N•m (71 lbf in). In-
stall the hose guards. Tighten the capscrews that
NOTE: This procedure is for the four-function option. mount the guards to 66 N•m (49 lbf ft).
The three-function option will have hoses A and B
only. 8. Position the hoses at the hose sheave. See Fig-
ure 41 and Figure 42. The hose sheave and stub-
NOTE: The carriage height must be correct before the shaft must be installed on the hose before they
header hoses can be adjusted. See Lift Chains Ad- are attached to the mast. Tighten the hardware
justment for the carriage adjustment procedure. to 53 N•m (39 lbf ft).
1. Mark each hose with a single letter: A, B, C, 9. Put the clamps over the hoses and attach the
or D. See Figure 34, Figure 40, Figure 41, and clamps to the upper brackets. (DO NOT tighten
Figure 42. the hardware.)
2. Use a calculator to calculate the dimensions E NOTE: To make the alignment of dimension G easier,
and G. See Figure 40. use a crane to raise the inner channel high enough to
3. Clamp the end of the hose (the smaller fitting) install a safety chain as shown in Figure 34.
that attaches to the carriage in a vise (do NOT 10. Align mark G on hoses A and D at the bottom
clamp on the threads), and pull on the other end edge of clamp to create the proper tension. Align
until the hose is straight. Do NOT apply enough mark G on hoses B and C at the top edge of clamp
force to stretch the hose. See Figure 40. to create the proper tension. Tighten the hard-
4. Mark the all the hoses with dimensions E and ware to 8 N•m (71 lbf in).
G (all measurements are made from the carriage 11. Install the clamps.
end of the hose [the smaller fitting]). See Fig-
ure 40. 12. Connect the header hoses to the cowl hoses.
5. Attach the hoses to the carriage bracket with 13. Use the rubber clamps and strap clamps to at-
clamps. See Figure 41. Apply spray lubricant tach the hoses to the main lift cylinders. Make
to the surface of the hose guide that contacts the sure the hoses do not stretch or fold while tilting
hoses. the mast fully forward and backward.
6. Place the hoses over the top of the free-lift 14. With no load on the forks, check the header hose
chains and under the hose guides. See Figure 41 adjustment by operating the mast through the
and Figure 42. Attach the hose guides to the full lift cycle two times. When properly adjusted,
lower crossmember and tighten the mounting the hoses will not be so tight that they compress
hardware to 33 N•m (24 lbf ft). Make sure the when they pass over the sheaves nor will they
bracket is between the crossmember and the be so loose that they touch the load backrest or
hose guide. Put the clamps over the hoses and any crossmember that is next to a sheave. If the
attach the clamps to the free-lift bracket. (DO hoses require additional adjustment, see Three-
NOT tighten the hardware.) Stage FFL Mast, Adjust Hoses After Install.
67
Figure 40. Header Hose Measurement, Three-Stage Full Free-Lift Mast
68

Class II Mast Type
Dimension E = (0.985 × Y) + (0.985 × Z) 350**
Example: Dimension E = (0.985 × Y) + (0.985 × Z) 350
Step 1. Dimension E = (0.985 × 3710) + (0.985 × 2095) 350
Step 2. Dimension E = 3654.4 + 2063.6 350
Step 3. Dimension E = 5718 350
** For Lift Heights of 3710 mm to 6110 mm. For Lift Heights of 6260 mm to 8510 mm, use 842.
Dimension G Calculations are similar to Dimension E
(1.965 × Y) + (0.985 × Z) 65
(1.965 × Y) + (0.985 × Z) 65

Class II Mast Type
Dimension E = (0.985 × Y) + (0.985 × Z) 8.781**
Example: Dimension E = (0.985 × Y) + (0.985 × Z) 8.781
Step 1. Dimension E = (0.985 × 146.1) + (0.985 × 82.5) 8.781
Step 2. Dimension E = 143.91 + 81.3 8.781
Step 3. Dimension E = 225.20 8.781
** For Lift Heights of 146.1 To 240.6. For Lift Heights of 246.5 to 335.0, use 33.156.
Dimension G for Lift Heights of 146.1 to 240.6:
(1.965 × Y) + (0.985 × Z) 2.562
(1.965 × Y) + (0.985 × Z) 2.562
69

Class III Mast Type
Dimension E = (0.985 × Y) + (0.985 × Z) 350**
(1.965 × Y) + (0.985 × Z) 65
(1.965 × Y) + (0.985 × Z) 65

Class III Mast Type
Dimension E = (0.985 × Y) + (0.985 × Z) 8.781**
Dimension G Calculations are similar to Dimension E
(1.965 × Y) + (0.985 × Z) 2.562
(1.965 × Y) + (0.985 × Z) 2.562
** For Lift Heights of 138.8 to 233.0. For Lift Heights of 238.9 to 327.5, use 33.156.
1. DIMENSION G 5. TOP OUTER CHANNEL

4. HOSE
70
Figure 41. Header Hoses, Three-Stage Full Free-Lift Mast
71

A. OLD STYLE
1. CAPSCREW 14. NUT
2. HOSE GUARD 15. CLAMP
3. SNAP RING 16. HEADER HOSES
4. HOSE GUIDE 17. FREE-LIFT CHAINS
5. FREE-LIFT CYLINDER CROSSHEAD 18. CLAMP
6. WASHER 19. COWL HOSES
7. SPACER 20. UPPER BRACKET
8. SHEAVE 21. CARRIAGE BRACKET
9. HOSE GUARD 22. CLAMP
10. CLAMP 23. STUBSHAFT
11. FREE-LIFT BRACKET 24. LOCK NUT
12. LOWER BRACKET 25. STRAP CLAMP
13. HOSE GUIDE
THREE-STAGE FFL MAST, ADJUST hoses is wrong, loosen the clamps and pull (if the
HOSES AFTER INSTALL hoses are too loose) or push (if the hoses are too
tight) on the hoses so they move 15 mm (0.6 in.),
1. If the tension of the hoses is correct between the plus the amount the hoses were moved in Step 1.
carriage and the clamp at the free-lift bracket, Tighten the hardware to 8 N•m (71 lbf in).
go to Step 2. If the tension of the hoses is wrong,
loosen the clamps and pull (if the hoses are loose) 3. With no load on the forks, check the header hose
or push (if the hoses are tight) on the hoses so adjustment by operating the mast through the
they move 15 mm (0.6 in.). Tighten the hardware full lift cycle two times. When properly adjusted,
to 8 N•m (71 lbf in). See Figure 34, Figure 40, the hoses will not be so tight that they compress
Figure 41, and Figure 42. when they pass over the sheaves nor will they be
so loose that they touch the load backrest or any
2. If the tension of the hoses is correct between the crossmember that is next to a sheave. If neces-
clamp at the upper bracket and the clamp at the sary, repeat Step 1 and Step 2 until the hoses are
free-lift bracket, go to Step 3. If the tension of the properly adjusted.
72
73
74
A. HOSE A G. LEFT-HAND CYLINDER

B. HOSE B H. ALIGN MARK E AT BOTTOM OF THIS CLAMP.
C. HOSE C I. REAR VIEW
D. HOSE D J. RIGHT-HAND CYLINDER
E. FRONT VIEW K. FORKS
F. ALIGN G ON HOSES A AND D AT BOTTOM OF
THIS CLAMP. ALIGN G ON HOSES B AND C AT
BOTTOM OF THIS CLAMP.
1. HOSE GUIDE 4. FREE-LIFT CYLINDER
2. HOSE 5. CYLINDER GUARD
3. BOTTOM CROSSMEMBER, INNER CHANNEL
75
Lift and Tilt System Leak Check 4000 SRM 522
Lift and Tilt System Leak Check

LIFT CYLINDERS LEAK CHECK lowers when the gate valve is open, check for
leaks in the hydraulic lines and fittings. If no
WARNING leaks are found, the main control valve can be
worn or damaged. Remove the load from the
During the test procedures for the hydraulic
forks.
system, use chains to fasten the load to the car-
riage to prevent it from falling. Keep all people
away from the lift truck during the tests.
TILT CYLINDERS LEAK CHECK
1. Put a capacity load on the forks. Slowly tilt the
Do NOT try to find hydraulic leaks by putting
mast forward. If the mast continues to slowly
your hand on hydraulic components under
tilt forward when the control valve is in the neu-
pressure. Hydraulic oil can be injected into
tral position, there are leaks inside the hydraulic
the body by the pressure.
system. The maximum speed that the mast is
1. Operate the hydraulic system. Put a capacity allowed to tilt forward when there are internal
load on the forks, and raise and lower the load leaks in the lift system is 13 mm (0.5 in.) per
several times. Lower the load and tilt the mast 10 minutes (measured at rod in the tilt cylinder).
forward and backward several times. Check for The maximum speed is measured when the hy-
leaks. draulic oil is 30 C (86 F). If the oil temperature
is 70 C (158 F), the maximum speed is 39 mm
2. Raise the carriage and load 1 m (3 ft). If the car- (1.5 in.) per 10 minutes.
riage slowly lowers when the control valve is in
the neutral position, there are leaks in the hy- 2. If the leak rate is greater than the specifications,
draulic system. The maximum speed that the remove the load from the mast. Install a gate
carriage is allowed to lower is 50 mm (2 in.) per valve between the port at the front of the tilt
10 minutes when the hydraulic oil is 30 C (86 F). cylinder and the hydraulic line. Put the load on
If the oil temperature is 70 C (158 F), the max- the forks again. Close the gate valve. If the mast
imum speed the carriage can lower is 150 mm tilts slowly forward, the cylinder seals are leak-
(6 in.) per 10 minutes. ing.
3. Check the lift cylinders for internal leaks. Re- 3. If the mast does not move, open the gate valve
move the load from the forks. Install a gate valve and check the movement again. If the mast
in the supply line between the main control valve moves forward when the gate valve is open,
and the mast. Put a capacity load on the forks check for leaks in the hydraulic lines and fit-
again. Raise the carriage 1 m (3 ft). Close the tings. If no leaks are found, the main control
gate valve. If the carriage or mast weldments valve can be worn or damaged. Remove the load
lower slowly, the seals in the lift cylinders have from the forks when the checks are complete.
leaks.
4. If the carriage does not move, open the gate valve

and check the movement again. If the carriage
76
4000 SRM 522 Tilt Cylinders Adjustment
Tilt Cylinders Adjustment

c. Slowly tilt the mast backward until one rod
WARNING end just contacts the spacer. Add shims to
When the tilt cylinders have tilt limit spacers, fill the gap at the opposite rod end until both
make sure they are installed during installa- rod ends contact the spacers within 0.5 mm
tion procedures. Without the tilt limit spacers, (0.02 in.).
the mast can tilt too much and cause an acci-
dent or serious injury. d. After the adjustments are complete, tighten
the capscrews on the rod ends.
Check the tilt cylinder stroke by slowly tilting the
mast fully forward and backward several times. Both e. Tilt the mast fully backward and measure
tilt cylinders must stop their stroke at the same time. the tilt angle. (See the nameplate for tilt
Adjust the rod ends as shown in Figure 43, Figure 44, angles.) If necessary, add an equal number
and Figure 45. There must be no twist in the mast of shims to both rods for the correct angle.
weldments.
1. Adjust the stroke of the tilt cylinders WITHOUT

tilt limit spacers as follows:
a. Adjust the rod ends to 15 mm (0.6 in.) for all

tilt cylinders shown in Figure 43, and 32 mm
(1.25 in.) for all tilt cylinders shown in Fig-
ure 45.
b. Slowly tilt the mast backward until one

cylinder rod stops. On the opposite cylinder,
loosen the capscrews on the rod end. Mea-
sure the distance from the end of cylinder to
the back end of the rod end. Use a wrench
and turn the cylinder rod IN until the dimen-
sion starts to decrease, then stop. Repeat
this procedure until both cylinder rods stop
at the same position within 1 mm (0.04 in.).
After the adjustments are complete, tighten
the capscrews on the rod ends.
c. Tilt the mast fully backward and measure

the tilt angle. (See the nameplate for tilt
angles.) If necessary, adjust both rod ends NOTE: THE END OF THE ROD IS EVEN WITH THE
equally for the correct angle. FRONT FACE OF THE ROD END.
2. Adjust the stroke of the tilt cylinders WITH tilt 1. MAST 3. TILT CYLINDER
limit spacers as follows: 2. ROD ENDS
a. Adjust the rod ends to 15 mm (0.6 in.) for all Figure 43. Tilt Cylinder Adjustment
tilt cylinders as shown in Figure 44. H/S1.50-1.75XM (H/S25-35XM), H/S2.00XMS
(H/S40XMS), E1.50-1.75XM (E25-35XM,
b. Slowly tilt the mast forward until one cylin- E25-35XM 2) (D114), and E2.00XMS (E40XMS,
der rod stops. On the opposite cylinder, E40XM 2S) (D114), and E1.50-2.00XM (E25-35Z,
loosen the capscrews on the rod end. Use E40ZS) (E114)
a wrench and turn the cylinder rod IN as
necessary. Repeat this procedure until both
cylinder rods stop at the same position
within 1 mm (0.04 in.).
77
Lift Chains Adjustment 4000 SRM 522
1. MAST 4. TILT LIMIT SPACER 1. MAST 3. TILT CYLINDER

2. ROD END 5. TILT CYLINDER 2. ROD ENDS
3. SHIMS
Figure 45. Tilt Cylinder Adjustment
Figure 44. Tilt Cylinder Adjustment J1.60-2.00XMT (J30-40ZT)
H/S2.00-3.20XM (H/S40-65XM), E2.00-3.20XM
(E40-65XM, E40-65XM 2) (F108), E2.00-3.20XM
(E45-65Z) (G108), J2.00-3.20XM (J40-60XM,
J40-60XM 2) (A216), J2.00-3.20XM (J40-65Z)
(A416), and S/E/J2.00-3.00XL (S/E/J40-60XL)
Lift Chains Adjustment

pressure. Hydraulic oil can be injected into
WARNING the body by the pressure.
When working on or near the mast, see Safety
Procedures When Working Near Mast in this When the lift chains are correctly adjusted:
section. • The tension will be the same on each chain of the
chain set. Check tension by pushing on both chains
During test procedures for the hydraulic sys- at the same time.
tem, fasten the load to the carriage with chains • The chain length will be correct.
to prevent it from falling. Keep all personnel • The chains must travel freely through the complete
away from the lift truck during the tests. cycle.
Never allow anyone under a raised carriage. NOTE: When the chain adjustments are complete,
DO NOT put any part of your body in or make sure the threads on the nuts of the chain an-
through the lift mechanism unless all parts chors are completely engaged. Make sure all of the
of the mast are completely lowered and the adjustment is not removed from the chain anchors.
engine is STOPPED. The chain anchors must be able to move on their
mounting.
Do not try to find hydraulic leaks by putting
your hand on hydraulic components under
78
4000 SRM 522 Lift Chains Adjustment
1. When adjusting the lift chains on forklift trucks Table 1. Hook-Type Carriage Chain Adjustment
equipped with either pin- or hook-type forks in-
stalled, go to Step 2. If the forklift truck is nor- Class II and III 82.5 ±3 mm (3.25 ±0.12 in.)
mally equipped with a hook-type carriage and
Class IV 133.5 ±3 mm (5.26 ±0.12 in.)
has an attachment without forks, go to Step 3.
If the forklift truck is normally equipped with a
pin-type carriage and has an attachment without
forks, go to Step 4.
NOTE: Prior to performing adjustment procedures,

make sure the forklift truck is parked on a level sur-
face and the mast is in the vertical position.
2. Adjust the chain anchors which support the car-

riage until the bottom of the fork heel is 6 ±3 mm
(0.24 ±0.12 in.) above the floor level. See Fig-
ure 46.
1. MAST
2. CARRIAGE
3. DISTANCE FROM FLOOR TO LOWER
CARRIAGE BAR
Figure 47. Lift Chain Adjustment, Hook-Type

Carriage
4. See Figure 48. Adjust the chain anchors, which

support the carriage, until the center line of the
fork pin is above the floor level as shown in Ta-
ble 2.
1. TILT MAST FULLY BACKWARD
2. CARRIAGE ROLLER Table 2. Pin-Type Carriage Chain Adjustment
3. FORK
4. CARRIAGE ROLLER MUST NOT EXTEND H70/80, 90XLS 545 ±3 mm (21.5 ±0.12 in.)
MORE THAN 34 mm (1.3 in.) BELOW INNER
MAST CHANNEL. H90-110XL 708 ±3 mm (27.87 ±0.12 in.)
Figure 46. Lift Chain Adjustment, Hook- or H135-155XL 907 ±3 mm (35.71 ±0.12 in.)
Pin-Type Forks
3. See Figure 47. Adjust the chain anchors which

support the carriage until the bottom of the lower
carriage bar is above the floor level as shown in
Table 1.
79
Mast Adjustment 4000 SRM 522

1. LOAD BACK REST
2. FORK PIN
3. DISTANCE FROM FORK PIN TO FLOOR
Figure 48. Lift Chain Adjustment, Pin-Type

Carriage
Mast Adjustment
NOTE: Shims are installed on both sides of the load b. Use shims to adjust the load rollers so there
rollers. Do not add or remove shims from the stub is zero clearance between the load roller and
shafts. To change the position of the roller on the the channel at the point of tightest fit.
stub shaft, move the shims from one side of the load
roller to the other. c. The number of shims under a load roller
must be approximately the same as the stub
During assembly, the shim arrangement will be ap- shaft in the opposite side of the weldment.
proximately the same as before disassembly. Check The weldments will be approximately in the
the clearance and adjust for wear or change due to center.
repairs.
2. Adjust the load rollers on the mast as follows:
1. The load rollers control the alignment of the mast
weldments. The alignment conditions are given a. Use a pry bar to move the mast weldments
on a list below, with the most important condition from side to side to measure the amount of
first. See Figure 49. movement. Repeat this step in a minimum
of three different positions (top, middle, bot-
a. The mast weldments must be parallel to each tom) of the mast weldments.
other.
80
4000 SRM 522 Mast Adjustment
b. Separate the mast weldments and change Change shims to keep the distance equal be-
the shim arrangements as needed. Assemble tween the top and bottom of the mast weld-
the mast weldments. Slide the mast weldments. Make sure the weldments are paral-
ment all the way to the top and bottom to find lel within 1.5 mm (0.06 in.).
the tightest fit.
3. Adjust the strip bearings. Insert shims between
c. Repeat Step a and Step b until there is zero the strip bearing and the channel. Adjust the
clearance at the point of tightest fit. strip bearings so the maximum clearance at the
point of tightest fit is 0.8 mm (0.031 in.). See
d. Measure the distance between the channels Figure 18.
of the mast weldments on the top and bottom.
A. TOP VIEW C. CARRIAGE FRONT VIEW

B. MAST FRONT VIEW
1. MAST WELDMENT (CHANNEL) 6. PARALLEL, EQUAL SPACE WITHIN 1.5 mm
2. LOAD ROLLER (0.06 in.)
3. SNAP RING 7. ADJUST LOAD ROLLERS FOR ZERO
4. SHIMS CLEARANCE
5. STUB SHAFT
Figure 49. Mast and Carriage Adjustments
81
Carriage Adjustment
1. Install the load rollers on the carriage. Install 3. Remove the carriage from the mast. Adjust the
the shims for the rollers in the same sequence on shim arrangement for each load roller for clear-
the stub shaft as before disassembly. When the ance between the load roller and the inner mast
carriage has six load rollers, there are no shims weldment. Repeat Step 1 and Step 2 until there
under the top load rollers. See Mast and Car- is zero clearance at the point of tightest fit.
riage Adjustments.
4. Keep the shim arrangement between the middle
and bottom load rollers on the same side of the
WARNING carriage approximately equal. Also keep the
The mast is heavy. The mast can weigh approx- shim arrangement on each side of the carriage
imately 681 kg (1501 lb). Make sure all lifting approximately equal. The carriage must be
devices (hoists, cables, chains, slings, etc.) are parallel with the inner mast weldment within
suitable and of adequate capacity to lift the mo- ±1.5 mm (±0.06 in.).
tor.
2. Use a crane to raise the carriage up the inner

mast weldment. Find the tightest fit between the
load rollers and the inner mast weldment.
Troubleshooting
No movement of the lift or Linkage at the control valve is dis- Connect and adjust linkage.
tilt cylinders. connected.
No oil or not enough oil in the hy- Fill tank. Check for leaks.
draulic tank.
Relief valve is not set correctly. Adjust or install new relief valve.
Hydraulic pump does not operate or Repair or install new pump.

has damage.
Slow movement of the lift or No oil or not enough oil to the lift Fill tank. Check for leaks.
tilt cylinders. cylinders.
Cylinders have internal or external Repair leaks. Install new parts.

leaks.
Relief valve is not set correctly. Adjust or install new relief valve.
There is a restriction in a hydraulic Remove restriction. Install new

line. parts.
Load is more than capacity. Reduce load.
Hydraulic control linkage is incor- Adjust the load.

rectly adjusted.
82
Rough movement of the mast There is air in the hydraulic system. Remove air. Check for loose connec-
assembly. tions or breaks in lines.
Lift cylinder(s) is damaged. Repair or install new lift cylinder.
Mast weldments are damaged or not Align weldments. Install new parts.
aligned.
Mast weldments are not lubricated Correct lubrication.

correctly.
83
NOTES
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84
4000 SRM 522 5/04 (11/03)(3/03)(5/01)(5/96)(11/94)(7/94)(2/94)(11/93)(4/93) Printed in United Kingdom

METRIC AND INCH
(SAE) FASTENERS
ALL MODELS
PART NO. 910442 8000 SRM 231

SAFETY PRECAUTIONS

trucks.
nance section.
manual:
WARNING
CAUTION
Metric and Inch (SAE) Fasteners Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Threaded Fasteners....................................................................................................................................... 1
Nomenclature, Threads................................................................................................................................. 1
Strength Identification .................................................................................................................................. 2
Cotter (Split) Pins.......................................................................................................................................... 2
Fastener Torque Tables ................................................................................................................................. 7
Conversion Table ........................................................................................................................................... 9
All Models

"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
8000 SRM 231 General
General
THREADED FASTENERS shown first in the series [M12 = 12 mm, M20 = 20
mm (1/2 = 1/2 in., 3/4 = 3/4 in.)].
Threaded fasteners, like bolts, nuts, capscrews, and
studs, are made to specifications that describe the The number of threads per inch is normally not
mechanical strength and hardness of the fastener. shown for inch nomenclature and only the UNC
A fastener used in a design application is selected (Unified National Coarse) or UNF (Unified National
according to its specifications. Hyster® Company Fine) is shown. This number of threads per inch is
buys parts from many countries. Parts that are not shown because a UNC or UNF fastener has a
purchased must be to Hyster® Company standards. standard number of threads per inch for a specific
There are several standards used by these countries diameter. Metric fasteners show the number of
in the manufacture of threaded fasteners. Many of threads per millimeter.
these fasteners are similar, but cannot be used as a
direct replacement. To make sure that you have the The length of the shank is often indicated as part of
correct fastener, order fasteners and parts through the description of a fastener. This length is shown
the Hyster® Parts Depot. in inches for inch fasteners and in millimeters for
metric fasteners.
Service persons must use replacement fasteners
that have the same specifications. Fasteners made A capscrew will have the following description:
to each specification have identification marks for
Metric Inch
that specification. This specification is commonly
called "Grade" for SAE standards and "property M12 × 1.75 × 50 1/2 × 13 UNC × 1-1/2
class" for metric standards. This section describes
ABC ABCD
the identification of some common fasteners.
A = Thread Size A = Shank Diameter
The metric system used by Hyster® Company is
described as SI (Le Systeme d’Unites or the In- B = Pitch B = Number of Threads
ternational System of units, also called SI in all Per Unit of Length
languages). The SI System of measurement is de- C = Length C = type of Thread
scribed in ISO Standard 1000, 1973. A conversion
table of common measurements is shown in Table 7. D = Shank Length
NOMENCLATURE, THREADS
The thread design is specified by a series of numbers
and letters for inch and metric fasteners. See Fig-
ure 1. The diameter of the shank of the fastener is
Figure 1. Thread Design
1
General 8000 SRM 231
STRENGTH IDENTIFICATION
CAUTION
When fasteners must be replaced, the new fas-
teners must be of the same strength or greater
than the original fasteners. The new fasteners
must also be the correct size.
NOTE: Identification marks are according to bolt

strength. The higher the number or the increase
in the number of marks indicates increased bolt Figure 2. Minimum Angle Between Cotter Pin
strength. Legs
The most common property classes for metric fasten- Unless otherwise specified, the legs of chain anchor
ers are 8.8 and 10.9. The property class is marked cotter (split) pins are to be bent against the pin. See
with a number on the head of the capscrew or on Figure 3.
a nut. Property classes less than 8.8 are often not
marked. Grades for inch bolts go from 2 to 8. Grade
2 fasteners normally do not have any marks. The
following tables show the marks that identify the
grades and property classes for different fasteners.
COTTER (SPLIT) PINS

Cotter (split) pins are used in many applications on
your forklift. They are typically used to retain parts
such as pins and nuts. Cotter (split) pins are typi-
cally not used as load-bearing members. Service per-
sonnel must use new cotter (split) pins. Do not reuse
a cotter (split) pin. Replacement cotter (split) pin
must be of the correct size. See Table 8.
The legs of a cotter (split) pin are bent for the follow-
ing reasons: 1. COTTER PIN
• To retain the cotter (split) pin in the part
Figure 3. Cotter (Split) Pins Used On Mast
• To provide clearance between the cotter pin legs
Chain Anchors
and other parts or members. One or both cotter
(split) pin legs must be bent to provide a minimum
90 angle between the legs. See Figure 2.
2
Table 1. Bolts and Screws
3
Table 2. Studs and Nuts
4
Table 3. Torque Nuts
5
Table 4. Torque Nuts With Nylon Insert
6
FASTENER TORQUE TABLES

Table 5. Torque Values for Metric Fasteners*
Property Class Grade Grade

Size and Pitch 5.8 1 8.8 2 10.9 3
N•m lbf ft N•m lbf ft N•m lbf ft
M3 × 0.5 0.62 0.5 0.99 0.7 1.34 1.0
M3.5 × 0.6 0.97 0.7 1.55 1.1 2.11 1.6
M4 × 0.7 1.44 1.1 2.30 2.1 3.13 2.3
M5 × 0.8 2.91 2.1 4.65 3.6 6.33 4.7
M6 × 1 4.94 3.6 7.90 6 10.8 8
M8 × 1.25 12.0 9 19.2 14 26.1 19
M8 × 1 12.8 9 20.5 15 27.9 21
M10 × 1.5 23.8 18 38.0 28 52 38
M10 × 1.25 25.1 19 40.1 30 55 41
M12 × 1.75 41.4 31 66 49 90 66
M12 × 1.25 45.3 33 72 53 98 72
M14 × 2 66 49 105 77 145 105
M14 × 1.5 72 53 115 85 155 115
M16 × 2 105 77 165 122 225 165
M16 × 1.5 110 81 175 130 240 175
M20 × 2.5 200 150 320 235 435 320
M20 × 1.5 225 165 355 260 485 360
M24 × 3 345 255 555 410 755 560
M24 × 2 375 275 605 445 820 605
M27 × 3 505 370 810 600 1,100 810
M27 × 2 550 405 875 645 1,190 880
M30 × 3.5 690 510 1,100 810 1,500 1,100
M30 × 3 715 530 1,140 840 1,550 1,140
M30 × 2 765 565 1,220 900 1,660 1,230
M33 × 3.5 940 695 1,500 1,100 2,040 1,510
M33 × 2 1,030 760 1,640 1,210 2,240 1,660
M36 × 4 1,200 885 1,930 1,430 2,620 1,940
M36 × 3 1,280 945 2,040 1,510 2,780 2,050
M39 × 4 1,560 1,150 2,490 1,840 3,390 2,500
M39 × 3 1,640 1,210 2,630 1,940 3,570 2,640
M42 × 4.5 1,930 1,430 3,080 2,280 4,200 3,100
M42 × 3 2,070 1,530 3,320 2,450 4,510 3,330
M45 × 4.5 2,410 1,780 3,850 2,840 5,240 3,870
M45 × 3 2,580 1,910 4,120 3,040 5,610 4,140
M48 × 5 2,900 2,140 4,630 3,420 6,300 4,650
M48 × 3 3,160 2,330 5,040 3,720 6,860 5,060
* Unless otherwise specified
1
Approximately equal to Grade 2
2
3
7
Table 6. Torque Values for Inch Fasteners*
Grade Grade Grade

Size and Pitch 21 52 83
lbf ft N•m lbf ft N•m lbf ft N•m
1/4 20 UNC 4 6 6 9 9 12
1/4 28 UNF 5 6 7 10 10 14
5/16 18 UNC 8 11 13 18 18 25
5/16 24 UNF 9 13 14 20 20 28
3/8 16 UNC 15 20 23 31 33 44
3/8 24 UNF 17 23 26 36 37 50
7/16 14 UNC 24 33 37 50 52 71
7/16 20 UNF 27 36 41 56 58 79
1/2 13 UNC 37 50 57 77 80 110
1/2 20 UNF 41 56 64 86 90 120
9/16 12 UNC 53 72 82 110 115 155
9/16 18 UNF 59 80 91 125 130 175
5/8 11 UNC 73 99 115 155 160 215
5/8 18 UNF 83 110 130 175 180 245
3/4 10 UNC 130 175 200 270 280 380
3/4 16 UNF 145 195 225 300 315 425
7/8 9 UNC 125 170 320 435 455 615
7/8 14 UNF 140 185 355 480 500 680
1 8 UNC 185 255 485 655 680 925
1 14 UNF 210 285 540 735 765 1,040
1-1/8 7 UNC 265 360 595 805 965 1,310
1-1/8 12 UNF 300 405 670 905 1,080 1,470
1-1/4 7 UNC 375 510 840 1,140 1,360 1,850
1-1/4 12 UNF 415 565 930 1,260 1,500 2,050
1-3/8 6 UNC 490 665 1,100 1,490 1,780 2,420
1-3/8 12 UNF 560 760 1,250 1,700 2,040 2,760
1-1/2 6 UNC 650 885 1,460 1,980 2,370 3,210
1-1/2 12 UNF 735 995 1,650 2,230 2,670 3,620
* Unless otherwise specified
1
Approximately equal to metric Property Class 5.8
2
3
8
CONVERSION TABLE
Table 7. Conversion Table for Metric and English Units
Multiply By To Get Multiply By To Get

Area
2 2 2 2 2
inches (in. ) × 6.452 = centimeters (cm ) centimeters (cm 2) × 0.155 = inches 2
(in. 2)
2
feet (ft 2) × 0.093 = meters 2
(m 2) meters 2
(m 2) × 10.764 = feet 2
(ft 2)
Linear
inches (in.) × 25.4 = millimeters (mm) millimeter (mm) × 0.039 = inches (in.)
feet (ft) × 0.305 = meters (m) meter (m) × 3.281 = feet (ft)
yards (yd) × 0.914 = meters (m) meter (m) × 1.094 = yards (yd)
miles (mi) × 1.609 = kilometers (km) kilometer (km) × 0.621 = miles (mi)
Mass
ounces (oz) × 28.35 = grams (g) grams (g) × 0.035 = ounces (oz)
pounds (lb) × 0.454 = kilograms (kg) kilograms (kg) × 2.205 = pounds (lb)
tons (2,000 lb) × 907.18 = kilograms (kg) kilograms (kg) × 0.001 = tons (2,000 lb)
tons (2,000 lb) × 0.907 = metric ton (t) metric ton (t) × 1.102 = tons (2,000 lb)
Power
horsepower (hp) × 0.746 = kilowatts (kW) kilowatts (kW) × 1.34 = horsepower (hp)
Pressure
2 2
pounds/in. (psi) × 6.895 = kilopascal (kPa) kilopascals (kPa) × 0.145 = pounds/in. (psi)
2 2
pounds/in. (psi) × 0.007 = megapascal (MPa) megapascals (MPa) × 145.04 = pounds/in. (psi)
Temperature
( Fahrenheit 32) × 0.56 = Celsius (C) ( Celsius × 1.8) +32 = Fahrenheit
Torque
pound inches (lbf in.) × 0.113 = Newton meter (N•m) Newton meter (N•m) × 8.851 = pound inches (lb f in.)
pound feet (lbf ft) × 1.356 = Newton meter (N•m) Newton meter (N•m) × 0.738 = pound feet (lb f ft)
Velocity
miles/hour (mph) × 1.609 = kilometer/hour (km/h) kilometer/hr (km/h) × 0.621 = miles/hour (mph)
Volume
3 3 3 3 3
inches (in. ) × 16.387 = centimeters (cm ) centimeters (cm 3) × 0.061 = inches 3
(in. 3)
3
inches (in. 3) × 0.016 = liters (l) liters (l) × 61.024 = inches 3
(in. 3)
quarts, U.S. (qt) × 0.946 = liters (l) liters (l) × 1.057 = quarts, U.S. (qt)
quarts, U.S. (qt) × 0.83 = quarts, Imp. (qt) quarts, Imp. (qt) × 1.205 = quarts, U.S. (qt)
gallons, U.S. (gal) × 3.785 = liters (l) liters (l) × 0.264 = gallons, U.S. (gal)
gallons, U.S. (gal) × 0.83 = gallons, Imp. (gal) gallons, Imp. (gal) × 1.205 = gallons, U.S. (gal)
ounces (oz) × 29.57 = milliliters (ml) milliliters (ml) × 0.034 = ounces (oz)
9
Table 8. Cotter Pin Dimensional Data
Nominal Shank Diameter Head Dia. Length of Recommended

Size A A B Extended Prong Hole Size
C
max min min max min min max
1.00 mm 0.90 mm 0.70 mm 1.50 mm 1.52 mm 0.25 mm 0.91 mm 1.37 mm
(0.031 in.) (0.035 in.) (0.028 in.) (0.060 in.) (0.060 in.) (0.01 in.) (0.036 in.) (0.054 in.)
10
Nominal Length Range Nominal Size - Part Numbers

Length L
1.00 mm 1.60 mm 2.00 mm 2.50 mm 3.20 mm
max min (0.031 in.) (0.047 in.) (0.062 in.) (0.094 in.) (0.125 in.)
6.35 mm 7.10 mm 5.50 mm 0221870 0221875
(0.250 in.) (0.280 in.) (0.217 in.)
9.525 mm 10.5 mm 8.80 mm 0221871 0221876
(0.375 in.) (0.413 in.) (0.345 in.)
12.7 mm 13.5 mm 11.5 mm 0221872 0221877 0015200 0015211 0015221
(0.500 in.) (0.530 in.) (0.453 in.)
19.05 mm 20.5 mm 18.3 mm 0221873 0221878 0015201 0015212 0015222
(0.750 in.) (0.807 in.) (0.720 in.)
25.4 mm 26.9 mm 23.9 mm 0221874 0221879 0015202 0015213 0015223
(1.000 in.) (1.060 in.) (0.940 in.)
31.75 mm 33.3 mm 29.2 mm 0015203 0015216 0015224
(1.250 in.) (1.310 in.) (1.150 in.)
38.1 mm 40.9 mm 36.6 mm 0015204 0015217 0015225
(1.500 in.) (1.610 in.) (1.440 in.)
44.45 mm 46.0 mm 42.9 mm 0015205 0015218 0015226
(1.750 in.) (1.810 in.) (1.690 in.)
50.8 mm 52.3 mm 49.3 mm 0015206 0015219 0015227
(2.000 in.) (2.060 in.) (1.940 in.)
57.15 mm 58.7 mm 55.1 mm 0015220 0056997
(2.250 in.) (2.310 in.) (2.170 in.)
63.5 mm 65.0 mm 62.0 mm 0221894 0015229
(2.500 in.) (2.560 in.) (2.440 in.)
69.85 mm 72.1 mm 68.3 mm 0015230
(2.750 in.) (2.840 in.) (2.690 in.)
76.2 mm 81.3 mm 74.7 mm 0015279
(3.000 in.) (3.200 in.) (2.940 in.)
88.9 mm 91.4 mm 87.4 mm
(3.500 in.) (3.600 in.) (3.440 in.)
101.6 mm 113.3 mm 98.8 mm
(4.000 in.) (4.460 in.) (3.890 in.)
11
Table 9. Cotter Pin Dimensional Data (Continued)

Length L
1.00 mm 1.60 mm 2.00 mm 2.50 mm 3.20 mm
127.0 mm 128.5 mm 123.7 mm
(5.000 in.) (5.060 in.) (4.870 in.)
152.4 mm 153.9 mm 5.460 mm
(6.000 in.) (3.060 in.) (138.7 in.)

Length L
4.00 mm 5.00 mm 6.30 mm 8.00 mm 9.52 mm
6.35 mm 7.10 mm 5.50 mm
(0.250 in.) (0.280 in.) (0.217 in.)
9.525 mm 10.5 mm 8.80 mm
(0.375 in.) (0.413 in.) (0.345 in.)
12.7 mm 13.5 mm 11.5 mm
(0.500 in.) (0.530 in.) (0.453 in.)
19.05 mm 20.5 mm 18.3 mm 0015232 0015241
(0.750 in.) (0.807 in.) (0.720 in.)
25.4 mm 26.9 mm 23.9 mm 0015233 0015242 0015251 0015261
(1.000 in.) (1.060 in.) (0.940 in.)
12
Table 10. Cotter Pin Dimensional Data (Continued)

Length L
4.00 mm 5.00 mm 6.30 mm 8.00 mm 9.52 mm
31.75 mm 33.3 mm 29.2 mm 0015234 0015243 0015252 0015262 0221884
(1.250 in.) (1.310 in.) (1.150 in.)
38.1 mm 40.9 mm 36.6 mm 0015235 0015244 0015253 0015263 0221885
(1.500 in.) (1.610 in.) (1.440 in.)
44.45 mm 46.0 mm 42.9 mm 0015236 0015245 0015254 0015264 0221886
(1.750 in.) (1.810 in.) (1.690 in.)
50.8 mm 52.3 mm 49.3 mm 0015237 0015246 0015255 0015265 0015271
(2.000 in.) (2.060 in.) (1.940 in.)
57.15 mm 58.7 mm 55.1 mm 0015238 0015247 0015256 0221880 0221887
(2.250 in.) (2.310 in.) (2.170 in.)
63.5 mm 65.0 mm 62.0 mm 0015240 0015248 0015257 0221881 0015273
(2.500 in.) (2.560 in.) (2.440 in.)
69.85 mm 72.1 mm 68.3 mm 0015280 0015249 0015258 0221882 0015286
(2.750 in.) (2.840 in.) (2.690 in.)
76.2 mm 81.3 mm 74.7 mm 0015283 0015250 0015259 0015267 0015272
(3.000 in.) (3.200 in.) (2.940 in.)
88.9 mm 91.4 mm 87.4 mm 0015239 0015284 0015266 0015274
(3.500 in.) (3.600 in.) (3.440 in.)
101.6 mm 113.3 mm 98.8 mm 0015301 0015260 0128754 0015275
(4.000 in.) (4.460 in.) (3.890 in.)
127.0 mm 128.5 mm 123.7 mm 0221883 0015277
(5.000 in.) (5.060 in.) (4.870 in.)
152.4 mm 153.9 mm 5.460 mm 0221888
(6.000 in.) (3.060 in.) (138.7 in.)
13
Nominal Length Length Range Nominal Size - Part Numbers

L
13.0 mm 16.00 mm
max min (0.500 in.) (0.625 in.)
19.05 mm 20.5 mm (0.807 in.) 18.3 mm (0.720 in.)
(0.750 in.)
25.4 mm (1.00 in.) 26.9 mm (1.060 in.) 23.9 mm (0.940 in.)
31.75 mm 33.3 mm (1.310 in.) 29.2 mm (1.150 in.)
(1.250 in.)
38.1 mm (1.500 in.) 40.9 mm (1.610 in.) 36.6 mm (1.440 in.)
44.45 mm 46.0 mm (1.810 in.) 42.9 mm (1.690 in.) 0221889
(1.750 in.)
50.8 mm (2.000 in.) 52.3 mm (2.060 in.) 49.3 mm (1.940 in.) 0221890
57.15 mm 58.7 mm (2.310 in.) 55.1 mm (2.170 in.) 0221891
(2.250 in.)
63.5 mm (2.500 in.) 65.0 mm (2.560 in.) 62.0 mm (2.440 in.) 0221892
69.85 mm 72.1 mm (2.840 in.) 68.3 mm (2.690 in.) 0221893 0221895
(2.750 in.)
76.2 mm (3.000 in.) 81.3 mm (3.200 in.) 74.7 mm (2.940 in.) 0015291 0221896
88.9 mm (3.500 in.) 91.4 mm (3.600 in.) 87.4 mm (3.440 in.) 0015292 0221897
101.6 mm 113.3 mm 98.8 mm (3.890 in.) 0015293 0221898
(4.000 in.) (4.460 in.)
127.0 mm 128.5 mm 123.7 mm 0015295 0221899
(5.000 in.) (5.060 in.) (4.870 in.)
152.4 mm 153.9 mm 138.7 mm 0015297 0221900
(6.000 in.) (3.060 in.) (5.460 in.)
14
8000 SRM 231 3/04 (3/03)(9/00)(3/98)(6/83) Printed in United Kingdom

PERIODIC
MAINTENANCE
J1.6-2.0XMT (J30-40ZT) [J160]
PART NO. 1554635 8000 SRM 1079

SAFETY PRECAUTIONS

trucks.
nance section.
manual:
WARNING
CAUTION
Periodic Maintenance Table of Contents
TABLE OF CONTENTS
Introduction........................................................................................................................................................ 1
General ........................................................................................................................................................... 1
How to Move Disabled Lift Truck ................................................................................................................. 3
How to Tow Lift Truck............................................................................................................................... 3
How to Put Lift Truck on Blocks................................................................................................................... 4
How to Raise Drive Tires .......................................................................................................................... 4
How to Raise Steer Tires........................................................................................................................... 5
Safety Procedures When Working Near Mast.................................................................................................. 5
Maintenance Schedule....................................................................................................................................... 7
Maintenance Procedures Every 8 Hours or Daily............................................................................................ 12
Checks With the Key Switch OFF ................................................................................................................ 12
Safety Labels and Decals .......................................................................................................................... 12
Frame ......................................................................................................................................................... 12
Wheels and Tires ....................................................................................................................................... 12
Mast, Carriage, and Forks ........................................................................................................................ 12
Hydraulic Oil Level and Leaks................................................................................................................. 13
Operator and Battery Restraints ............................................................................................................. 14
Battery Check............................................................................................................................................ 14
Checks With the Key Switch ON .................................................................................................................. 15
Electrical Components .............................................................................................................................. 15
Directional Speed Control......................................................................................................................... 15
Steering System ........................................................................................................................................ 15
Hydraulic System ...................................................................................................................................... 15
Brakes ........................................................................................................................................................ 16
Maintenance Procedures Every 500 Hours or 3 Months ................................................................................. 16
Tire and Wheel Assemblies ........................................................................................................................... 16
Mast and Carriage......................................................................................................................................... 16
Battery ........................................................................................................................................................... 17
Parking Brakes .............................................................................................................................................. 18
Transaxle........................................................................................................................................................ 19
Maintenance Procedures Every 1000 Hours or 6 Months ............................................................................... 20
Lift Chains ..................................................................................................................................................... 20
Hydraulic Breather Cap ................................................................................................................................ 20
Master Cylinder............................................................................................................................................. 21
Electrical Inspection...................................................................................................................................... 21
Hydraulic Motor Brushes.......................................................................................................................... 21
Contactors.................................................................................................................................................. 21
Directional Speed Control......................................................................................................................... 22
Transaxle, Oil Change ................................................................................................................................... 22
Maintenance Procedures Every 2000 Hours or Yearly .................................................................................... 23
Steering .......................................................................................................................................................... 23
Hydraulic........................................................................................................................................................ 24
Hydraulic Oil Filter, Change .................................................................................................................... 24
Hydraulic Oil Strainer, Check .................................................................................................................. 24
Hydraulic Oil, Change .............................................................................................................................. 24
General Repairs ................................................................................................................................................. 25
Welding Repairs............................................................................................................................................. 25
Painting Instructions .................................................................................................................................... 26
Lift and Tilt System Leak Check ...................................................................................................................... 26
Lift System..................................................................................................................................................... 26

Table of Contents Periodic Maintenance

Tilt System ..................................................................................................................................................... 27
Battery Maintenance ......................................................................................................................................... 28
How to Charge Battery.................................................................................................................................. 28
How to Change Battery ................................................................................................................................. 29
Battery Size Specifications............................................................................................................................ 29
J1.6-2.0XMT (J30-40ZT) [J160]
ii
Introduction
GENERAL Your local dealer has the trained personnel and
equipment to conduct a complete program of inspec-
This section contains the instructions for periodic tion, lubrication, and maintenance. This program
maintenance and inspection and a maintenance will help your truck operate at its peak performance
schedule. and increase the life span of its components.
The maintenance schedule has time intervals for in- Throughout this section, forward will refer to travel
spection, lubrication, and periodic maintenance. The in the direction of the forks and left and right will be
time intervals are based on normal operation. Nor- determined by sitting in the seat facing forward. See
mal operation is considered to be one 8-hour shift per Figure 1.
day in a relatively clean environment on an improved
surface. Multiple shifts or dirty operating conditions DISCHARGING THE CAPACITORS
will reduce the recommended time intervals between
services.
WARNING
WARNING are properly trained and have authorization to
Do not make repairs or adjustments unless you do so. Repairs and adjustments that are not
are properly trained and have authorization to correct can create dangerous operating condi-
do so. Repairs and adjustments that are not tions. Do not operate a lift truck that needs re-
correct can create dangerous operating condi- pairs. Report the need for repairs to your su-
tions. Do not operate a lift truck that needs re- pervisor immediately. If repair is necessary, at-
pairs. Report the need for repairs to your su- tach a DO NOT OPERATE tag to the steering
pervisor immediately. If repair is necessary, at- wheel and remove the key.
tach a DO NOT OPERATE tag to the steering
WARNING
Some users have service personnel and facilities to Disconnect the battery before opening the elec-
perform the procedures listed in the maintenance trical compartment cover or inspecting or re-
schedule. Service manuals are available from your pairing the electrical system. If a tool causes
local dealer to help users who perform their own a short circuit, the high current flow from the
repairs. battery can cause personal injury or property
damage.
WARNING
Some checks and adjustments are performed
with the battery connected. Do not connect the
WARNING
or adjustments.
1
WARNING
been disconnected.
CAUTION
nect the battery and discharge the capacitor.
NEVER put power to the controller while any
power wires are disconnected. NEVER short
dure when servicing the controller. 1. POSITIVE CONNECTION (BT+)
1. Block load wheels to prevent lift truck from mov- 3. INSULATED JUMPER WIRES
ing. 4. 200-OHM, 2-WATT RESISTOR
2. Turn key switch to OFF position and disconnect Figure 2. Discharging the Capacitors
the battery. (Standard)

compartment door.

hinges.
WARNING


using insulated jumper wires. See Figure 2. 1. POSITIVE CONNECTION (BT+)
6. Remove the 200-ohm, 2-watt resistor before re- (Premium)
2
HOW TO MOVE DISABLED LIFT TRUCK 3. Turn the key switch to the OFF position and dis-
connect the battery by pressing the emergency
How to Tow Lift Truck disconnect switch to the STOP position.
4. Position blocks in front of and behind the drive

WARNING
tires to prevent unexpected movement.
Use extra caution when moving a lift truck dur-
ing the following conditions: 5. Locate the parking brake connectors (BRK_RUN
• Brakes do not operate correctly. 1, BRK_RUN 2, and the BRK_TOWING) beside
• Steering does not operate correctly. the brake diode on the main wiring harness.
• Tires are damaged. These items are found near the front, right
• Traction conditions are bad. wheel well. See Figure 4.
• Moving the lift truck 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 dif-
ficult. 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 1. BRK_RUN 1 4. BRAKE DIODE
truck MUST have a rated capacity equal to 2. BRK_RUN 2 5. MAIN WIRING
or greater than the weight of the disabled 3. BRK_TOWING HARNESS
lift truck. The capacity must be for a load
center equal to half the width of the disabled Figure 4. Brake Diode and Release Connectors
lift truck. See the nameplate of the disabled 6. If a charged battery is not installed in the lift
lift truck for the approximate total weight. truck, use special tool - Auxiliary Battery Con-
The forks must extend the full width of the nector (Hyster™ P/N 1564329) and an auxiliary
disabled lift truck. Center the weight of the 24-volt power supply to energize the brake over-
disabled lift truck on the forks and be careful ride circuit:
not to damage the under side of the lift truck.
a. Disconnect the BRK_RUN 1 and BRK_RUN
NOTE: The towed lift truck must have an operator 2 connectors.
and an adequately charged battery to energize the
parking brake coils. Tow the lift truck slowly. b. Connect the auxiliary battery connector to
the BRK_RUN 2 connector.
1. Raise the carriage and forks approximately
30 cm (12 in.) from the surface. Install a chain c. Connect the jumper wires to the 24-volt aux-
to prevent the carriage and mast channels from iliary power source and listen for the parking
moving. brakes to release.
2. If another lift truck is used to tow the disabled lift 7. If a charged battery is installed in the lift truck,
truck, it must have a weight equal to or greater use the BRK_TOWING connector to energize the
than that of the disabled lift truck. Install an ap- brake override circuit:
proximate half-capacity load on the forks of the
lift truck that is being used to tow the disabled a. Disconnect the BRK_RUN 1 and BRK_RUN
lift truck. This half-capacity load will increase 2 connectors.
the traction of the towing lift truck. Keep the
load as low as possible. b. Connect the BRK_TOWING and BRK_RUN
2 connectors.
3
c. Pull the emergency disconnect switch to the of the following assemblies will cause large
RUN position and listen for the parking changes in the center of gravity: mast and
brakes to release. load axle, battery, and counterweight. Put
the lift truck on blocks only if the surface is
8. Use a towing link made of steel that attaches to solid, even, and level. Make sure that any
the tow pins in the counterweights of both lift blocks used to support the lift truck are solid,
trucks. one-piece hardwood blocks. Put blocks in front
and back of the tires to prevent unexpected
NOTE: Tow slowly and listen for sounds other than
movement of the lift truck.
normal. If the parking brakes do not release or there
are other signs of damage (noises), stop towing and 1. Block the steer tires to prevent movement of the
repair on site or carry the lift truck using a larger lift truck. See Figure 5.
lift truck if necessary. When repairs are complete,
return the brake connectors to operation mode and 2. Use a hydraulic jack under each side of the frame
test for proper operation before returning to service. near the front. Make sure each jack has a ca-
pacity equal to at least half the weight of the lift
HOW TO PUT LIFT TRUCK ON BLOCKS truck. See the nameplate for weight specifica-
tions.
How to Raise Drive Tires
3. Put a block under each outer mast channel.
WARNING 4. Put additional blocks under the frame behind the
The lift truck must be put on blocks for some drive tires.
types of maintenance and repair. The removal
1. DRIVE TIRES 2. STEER TIRES
Figure 5. Putting Lift Truck on Blocks
4
8000 SRM 1079 Safety Procedures When Working Near Mast
How to Raise Steer Tires guard is removed, these lift points can be used to
raise the steer tire so blocks can be positioned un-
WARNING der the frame.
The lift truck must be put on blocks for some 1. Put blocks in front and back of the drive tires to
types of maintenance and repair. The removal prevent movement of the lift truck. See Figure 5.
of the following assemblies will cause large
changes in the center of gravity: mast and 2. Use hydraulic jacks to raise the steer tire. Posi-
load axle, battery, and counterweight. Put tion a jack under each side of the frame near the
the lift truck on blocks only if the surface is counterweight to raise the lift truck. DO NOT
solid, even, and level. Make sure that any place jacks under the counterweight. Make sure
blocks used to support the lift truck are solid, that the jacks have a total capacity of at least 2/3
one-piece hardwood blocks. Put blocks in front of the total weight of the lift truck as shown on
and back of the tires to prevent movement of the nameplate.
the lift truck.
3. Place blocks under the frame to support the lift
NOTE: The counterweight has lifting eyes, on which truck. DO NOT place blocks under the counter-
the overhead guard is mounted. When the overhead weight.
Safety Procedures When Working Near Mast

The following procedures must be used when inspect- 1. Lower the mast and carriage completely. Push
ing or working near the mast. Additional precautions the lift/lower control lever forward and make
and procedures may be required when repairing or sure there is no movement in the mast. Make
removing the mast. sure that all parts of the mast that move are
fully lowered.
WARNING OR
Mast parts are heavy and can shift. Distances
between parts are small. Serious injury or 2. If parts of the mast must be in raised position,
death can result if part of the body is hit by install a safety chain to restrain the moving parts
parts of the mast or the carriage. of the mast. Connect moving parts to a part that
• Never put any part of the body into or under does not move. Follow these procedures:
the mast or carriage unless all parts are com-
pletely lowered or a safety chain is PROP- a. Put the mast in a vertical position.
ERLY INSTALLED. Also, make sure that the b. Raise the mast to align the bottom cross-
key switch is in the OFF position and the bat- member of the weldment that moves in the
tery connector is disconnected. Attach a DO outer weldment with a crossmember on the
NOT OPERATE tag to the steering wheel. outer weldment. On the two-stage mast, the
• Be careful of the forks. When the mast is moving part is the inner weldment. On the
raised, the forks can be at a height to cause three-stage mast, it is the intermediate weld-
an injury. ment. On the four-stage mast, it is the first
• DO NOT climb on the mast or lift truck at any intermediate weldment. See Figure 6.
time. Use a ladder or personnel lift to work
on the mast. c. Use a 9.4 mm (0.370 in.) minimum safety
• DO NOT use blocks to support the mast weld- chain with a hook to fasten the crossmem-
ments or to restrain their movement. bers together so the movable member cannot
• Mast repairs require disassembly and re- lower. Put the hook on the back side of the
moval of parts and may require removal of mast. Make sure the hook is completely en-
the mast or carriage. Follow the repair pro- gaged with a link in the chain. Make sure
cedures in the proper section for each mast. the safety chain does not touch lift chains or
chain sheaves, tubes, hoses, fittings, or other
WHEN WORKING NEAR THE MAST, ALWAYS: parts on the mast.
5
Safety Procedures When Working Near Mast 8000 SRM 1079
Figure 6. Safety Chaining the Mast
6
8000 SRM 1079 Maintenance Schedule
Legend for Figure 6

A. TWO-STAGE MAST C. THREE-STAGE MAST
B. FREE-LIFT MAST D. FOUR-STAGE MAST
1. OUTER WELDMENT 5. HOOK
2. INNER WELDMENT 6. FREE-LIFT CYLINDER
3. INTERMEDIATE WELDMENT 7. CROSSMEMBER
4. FIRST INTERMEDIATE WELDMENT 8. CROSSMEMBER
d. Install another safety chain [9.4 mm 3. Turn the key switch to the OFF position and
(0.370 in.) minimum] between the top or disconnect the battery. Attach a DO NOT RE-
bottom crossmember of the carriage and a MOVE tag from the safety chain(s).
crossmember on the outer weldment.
e. Lower the mast until there is tension in the

safety chain(s) and the free-lift cylinder (free-
lift masts only) is completely retracted.
Maintenance Schedule
Figure 7. Maintenance Points
7
Maintenance Schedule 8000 SRM 1079
Table 1. Maintenance Schedule
Item Item 8 hr 500 hr 1000 hr 2000 hr Procedure or Specification

No. or or or or Quantity
1 day 3 3 6 1 year 3
months 3 months 3
1 Safety Labels and X Replace if See Parts Manual
Operating Manual Necessary
2 Frame, Covers, and X Visually Inspect Repair as Required
Floor Plates for Damage
3 Drive Tire and
Wheel Assemblies
Tire and Wheel X Check Condition Remove Foreign
Objects Embedded
in Tire
Lug Bolt Torque X7 Tighten if 170 N•m (125 lbf ft)
Required
4 Steering Tire and
Wheel Assemblies
Tire and Wheel X Check Condition Remove Foreign
Objects Embedded
in Tire
Lug Nut Torque X7 Tighten if 170 N•m (125 lbf ft)
Required
X = Check C = Change L = Lubricate
1
Equalization Charge approximately each month but not more than each week
2
Multipurpose Grease with 2-4% Molybdenum Disulfide for normal operations
3
Whichever comes first
4
Low temperature hydraulic oil where applicable (HCE-79)
5
Service after initial 50 hrs and at the recommended intervals thereafter
6
7
When installing, check after every 2-5 hrs until nuts stay tight for an 8-hr shift. Check every 500 hrs
or 3 months thereafter.
NOTE: Never use steam to clean electrical parts.
8
Table 1. Maintenance Schedule (Continued)

1 day 3 3 6 1 year 3
months 3 months 3
5 Mast X Inspect for Check Operation
Visible Damage
Pivots, Sliding L As Required Multipurpose Grease 2
Surfaces
Trunnion X Tighten if 35 N•m (26 lbf ft)
Capscrews Required
Trunnion Bush L 2 Lube Fittings Multipurpose Grease 2
Lift Chains X Inspect for Replace if Necessary
Visible Damage
X Check Stretch Replace if Necessary
L Lubricate as SAE 20 or 30
Required Engine Oil
6 Carriage Assembly X Inspect for Check Operation
Visible Damage
Forks X Check for Replace if Necessary
Damage
Fork Guides and X Check Operation Repair as Required
Locks
L Lubricate as Silicone Spray
Required Lubricant
Sideshift Wear X Check/Replace 2.38 mm (0.09 in.)
Bearings Four Places Minimum Thickness
7 Battery X Check Level Distilled Water
1
X Equalization
Charge
1
2
3
4
5
6
7
9
Maintenance Schedule 8000 SRM 1079

1 day 3 3 6 1 year 3
months 3 months 3
8 Steering System X Check Operation
X Check for Leaks
Steering Actuator X Tighten if 290 N•m (215 lbf ft)
Capscrews Required
9 Hydraulic System X Check Operation Repair as Required
X Check for Leaks
Hydraulic Oil X C 17.8 liter (4.7 gal) Hydraulic Oil - ISO
VG 46 (HCE-140)
Filter C5 Change Filter See Parts Manual
Breather Cap X Clean or Replace See Parts Manual
Hydraulic Motor X Check Condition 1.5 mm (.060 in.) From
Brushes Holder (Min.)
Hydraulic Oil C Clean or Replace See Parts Manual
Strainer
10 Pedals, Seat X Check Operation Repair as Required
Assembly, Hood,
L As Required Silicone Spray
Hinges, and Hood
Lubricant
latch
11 Service Brake X Check Operation Hydraulic Oil - ISO
VG 46 (HCE-140) 4
X Check for Leaks
1
2
3
4
5
6
7
10

1 day 3 3 6 1 year 3
months 3 months 3
12 Parking Brake X Check Operation
X Check Hold on 15% Grade (Max Load)
Grade
Air Gap X Measure Air Gap 0.30-0.46 mm
(0.012-0.018 in.)
13 Directional/Speed X L Check Operation Silicone Spray
Control Lubricant
14 Electrical Circuits
Horn, Lights, and X Check Operation Repair as Required
Alarms
Display Panel X Check Operation Troubleshoot
Electrical System
Contactors X Check Condition Repair as Required
15 Transaxle
Oil Level X6 C6 0.35 liter Hydraulic Oil
(0.37 qt) Each JDM J20
(HCE 102)
Breather X Clean and Check
Operation
1
2
3
4
5
6
7
11
Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1079
Maintenance Procedures Every 8 Hours or Daily

CHECKS WITH THE KEY SWITCH OFF condition of the frame, especially around welds, for
rust, cracks, or other damage. The overhead guard
WARNING must be free from defects to ensure protection to the
operator. A variety of covers and floor plates provide
protection and allow easy access to systems located
inside and around the frame. Make certain that all
disconnected. To prevent electrical shock and
covers and floor plates are present and secured in
injury, discharge the capacitor before inspect-
their proper locations.
ing or repairing any component in the electri-
cal compartment. Wear safety glasses. Make
certain the battery has been disconnected.
Wheels and Tires
Park the lift truck on a level surface. Lower the forks, WARNING
turn the key switch to the OFF position, and discon- When installing the wheels, check all wheel
nect the battery connector. Check for leaks and con- nuts after 2 to 5 hours of operation. Tighten
ditions that are not normal. Clean up any oil spills. the nuts in a cross pattern to the correct torque
value. When the nuts stay tight after an 8-hour
NOTE: Be certain to read and understand the infor-
check, the interval for checking the torque can
mation covered in the introduction section before per-
be extended to 500 hours or 3 months.
forming any of the maintenance procedures listed be-
low. Inspect the drive tires and wheel assemblies and the
steer tire and wheel assemblies for damage. Look
Make the following checks:
for deep grooves or cuts in the tires. Remove objects
• Condition of the safety labels and decals
embedded in the tire, such as wire, rocks, glass, and
• Condition of the frame, including the overhead
pieces of metal that can cause damage. Remove any
guard and counterweight
wire, strapping, or other material that is wrapped
• Condition of the wheels and tires
around the axle to prevent damage to the transaxle
• Condition of the mast, including the carriage and
seals. Inspect wheel rims for rust or cracks and check
forks
for loose or missing lug nuts and broken studs. DO
• Hydraulic oil level and fluid leaks
NOT operate a lift truck with damage to any wheel
• Operation of safety components, including the seat,
rim, lug nuts, or studs.
seat belt, battery restraint, and latch
• Electrolyte level and correct battery size and Mast, Carriage, and Forks
weight for the lift truck
Safety Labels and Decals WARNING

Special precautions are required when work-
WARNING ing on or near the mast or carriage. See Safety
Procedures When Working Near Mast.
If labels that have warnings or instructions are
damaged, they must be replaced immediately. 1. Inspect the welds on the mast and carriage for
cracks. Make sure that the capscrews and nuts
Safety labels are installed on the lift truck to give
are tight.
information about possible hazards. Check that all
safety labels are installed in the correct locations on 2. Inspect the channels for wear in the areas where
the lift truck. Make sure that no labels are damaged the rollers travel. Check the rollers for wear or
and that all labels can be read. See Frame 100 SRM damage.
1073 for information on replacing labels and decals.
3. Inspect the load backrest extension for cracks
Frame and damage.
The frame is a single weldment with mounts for the 4. Lubricate the lift chains with SAE 20 or 30 en-
counterweight, overhead guard, mast, steering sys- gine oil if necessary. Lubrication of chains is
tem, hydraulic system, and transaxles. Check the
12
8000 SRM 1079 Maintenance Procedures Every 8 Hours or Daily
regularly performed at the 500-hr/3-month inter- damaged or broken fork lock pins or components
val but may be lubricated earlier if needed. and lubricate as necessary.
5. Inspect the lift chains for cracks or broken links Hydraulic Oil Level and Leaks
and pins. See Figure 8.
WARNING
The hydraulic oil is HOT at normal operat-
ing temperature and can cause severe burns.
Avoid contact between hot oil and unprotected
skin.
Hydraulic oil under pressure can be injected

into the skin. Never check for leaks by putting
hands on hydraulic lines or components under
pressure.
CAUTION
Protect the hydraulic system from dirt and
contaminants when servicing the hydraulic
system.
Never operate the pump without the proper

amount of oil in the hydraulic system. The
1. WARPED PIN 5. LOOSE LEAVES operation of the hydraulic pump with low oil
2. CRACKS 6. DAMAGED PIN levels will damage the pump.
3. EDGE WEAR 7. CORROSION
4. HOLE WEAR The hydraulic, steering, and brake systems use
hydraulic oil to operate. The hydraulic and steering
Figure 8. Lift Chains Check systems draw oil from the hydraulic tank, circu-
6. Inspect the chain anchors and pins for cracks and late it through their systems, and return it into
damage. the hydraulic tank. The brake system also uses
hydraulic oil but is a self-contained system. An
7. Make sure the lift chains are adjusted so they indicator light notifies the operator when the brake
have equal tension. Adjustment or replacement system hydraulic oil level is too low. The hydraulic
of lift chains must be performed by properly oil for the brake system is contained in the master
trained, authorized service personnel. cylinder reservoir. Check for leaks by looking for
oil under the lift truck and where the lift truck has
been parked. Remove the floor mat and floor plates
WARNING to inspect the brake lines, master cylinder, steering
Never repair damaged forks by heating or pump, hydraulic tank, hydraulic pump, and hoses.
welding. Forks are made of tempered steel Oil leaks may appear as wet, oily leaks or unusually
using special procedures. Replace damaged dirty areas where dirt and dust sticks to oil that has
forks. slowly leaked out.
8. Inspect the forks for cracks and wear. Check Check the hydraulic oil level when the carriage is
the alignment of the fork tips. The difference in lowered and the key switch is in the OFF position.
height of the fork tips must be less than three Remove the breather cap/dipstick from the top of the
percent of the length of the forks. Some applica- hydraulic tank. Wipe the dipstick clean and rein-
tions may require closer alignment. If the forks stall the breather cap/dipstick into the tank. Remove
do not meet specification, they must be replaced. again and check the oil level. Add hydraulic oil only
Check that the bottom of each fork is not exces- as needed. If more hydraulic oil is added than the
sively worn. Check for smooth and proper oper- FULL level, hydraulic oil will leak from the breather
ation of the fork lock pins. Repair or replace any during operation.
13
Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1079
Operator and Battery Restraints Battery Check

The hood functions as a battery restraint to hold the
battery in the battery compartment if an accident WARNING
causes the lift truck to tip over. Two hinges at the Make sure the key switch is in the OFF position
back of the hood attach it to the frame. A sliding latch and the directional lever is in the NEUTRAL
mechanism on the front of the hood locks it closed position before connecting the battery. If the
during operation. See Figure 9. The latch can be ac- lift truck was operated with a discharged bat-
cessed by releasing and raising the hydraulic levers tery, check all contactors for welded tips BE-
and linkage assembly up and out of the way. The FORE a charged battery is connected.
latch must be in good condition and properly secured
before the lift truck can be operated. If the latch does WARNING
not lock the hood in the closed position, the hydraulic
Do not put tools on the battery. Metallic ob-
levers and linkage assembly will not lock into posi-
ject on the battery can cause a short circuit and
tion and the lift truck will not operate.
possible damage or injury.
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 solu-
tion of sodium bicarbonate (baking soda). Ar-
eas where acid has contacted the skin should
be flushed with water immediately. Acid in the
eyes must be flushed with water continuously
for 10 minutes; then seek medical attention.
Batteries generate explosive fumes. Keep the

vents in the caps clean. Keep sparks or open
flames away from the battery area. Be care-
ful not to make sparks when disconnecting the
battery connections. Disconnect the battery
when performing 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.
Make sure the battery weight ranges between the

1. SLIDING LATCH MECHANISM maximum and minimum weight shown on the Name-
2. HOOD plate. Check that the battery is charged and has the
3. FRAME correct voltage and ampere-hour rating for the lift
truck as shown on the Nameplate. Keep the battery
Figure 9. Latch Mechanism
case, top cover, and the area for the battery clean and
The hood, seat belt, hip restraint brackets, seat, and painted. Leakage and corrosion from the battery can
seat mounts are all parts of the operator restraint cause a malfunction in the electric controls of the lift
system. Check that the seat and mounts are securely truck. Use a water and sodium bicarbonate solution
mounted to the hood. The adjustment functions of (baking soda) to clean the battery and the battery
the seat should release and move smoothly, and en- area. Keep the top of the battery clean, dry, and free
gage securely. Check the seat belt for cuts or frays of corrosion. Inspect the battery case, connector, and
and make certain that it buckles securely and re- cables for damage, cracks, or breaks. See your local
leases smoothly. battery dealer to repair any damage.
14
8000 SRM 1079 Maintenance Procedures Every 8 Hours or Daily
Check the level of the electrolyte daily on a minimum and speed by pressing on the left side of the pedal.
of one cell. Choose a cell at random. The electrolyte Reverse is controlled by depressing the right hand
level should be halfway between the top of the plates side of the pedal. The amount of pressure on either
and the bottom of the fill hole. Add only distilled side of the pedal determines the acceleration rate.
water. If the level in the cell checked is low, check
all the cells and add distilled water as needed. Steering System
CHECKS WITH THE KEY SWITCH ON The steering system should operate when a properly
charged battery is connected, an operator is present
After completing the Checks With the Key Switch in the seat, and the key switch is in the ON position.
OFF, perform the Checks With the Key Switch ON Move the steering tire and wheel assembly com-
before placing the lift truck into service. pletely to the left by turning the steering wheel. The
assembly should turn smoothly to its stop. The steer-
Electrical Components ing tire should stop approximately parallel to the
battery. Turn the steering tire and wheel assembly
Turning the key switch to the ON position energizes completely to its right hand stop using the steering
the electrical systems of the lift truck. The horn, ac- wheel. The steering system should move smoothly
tivated by a switch located in the steering wheel cap, and make a full range of motion from its full left to
must operate to ensure safe operations by alerting full right position (approximately 180 degrees).
persons nearby that you are operating the lift truck
in their immediate area. Lift trucks may be equipped Hydraulic System
with backup alarms and visual alerts such as a strobe
light. Check that all lighting and alarms are operat-
ing properly before placing the lift truck into service. WARNING
The hydraulic oil is HOT at normal operat-
The display panel, located on the dash at the front of ing temperature and can cause severe burns.
the operator’s compartment, is also energized when Avoid contact between hot oil and unprotected
the key switch is turned to the ON position. The dis- skin.
play is essential to safe and productive operation of
the lift truck. Systems such as the battery condition Hydraulic oil under pressure can be injected
and fault codes are monitored by the controller and into the skin. Never check for leaks by putting
are expressed by the display. A malfunctioning dis- hands on hydraulic lines or components under
play unit may not alert an operator to a condition in pressure.
time to prevent damage to system components on the
lift truck. CAUTION
Directional Speed Control Protect the hydraulic system from dirt and
contaminants when the oil level is checked or
On standard models, a directional control lever is lo- the filter is changed.
cated on the steering column. Turn the key switch to
the ON position; place the directional control lever Never operate the pump without the proper
in the forward position. Gently press the accelerator amount of oil in the hydraulic system. The
pedal on the right hand floor of the operator’s com- operation of the hydraulic pump with low oil
partment. The truck should begin to smoothly move levels will damage the pump.
forward. Stop the truck, place the directional control Check the hydraulic system by sitting in the seat to
lever in the reverse position, and gently press the ac- close the seat switch and turning the key switch to
celerator. The truck should now move in reverse. the ON position. Raise and lower the mast repeat-
Premium models control the direction of travel and edly. The mast should move smoothly and should not
acceleration with the MONOTROL™ foot pedal. bounce or jerk when stopping or starting. Check each
This two-function pedal controls forward direction function of the control valve for proper operation.
15
Maintenance Procedures Every 500 Hours or 3 Months 8000 SRM 1079
Brakes The parking brakes are engaged at all times when

the truck is stopped. Turning the key switch to the
Check the service brakes for proper operation by OFF position or pressing the emergency disconnect
slowly moving the lift truck in a safe direction and button on the hood will also cause the parking brakes
apply the service brake by pressing the brake pedal. to immediately apply. Move the lift truck slowly in a
The lift truck should stop quickly. If the lift truck safe direction and listen for signs the parking brakes
does not stop properly or if the brake pedal feels soft are dragging. Allow the truck to stop and listen for
or spongy, troubleshoot the service brake system. the "click" of the parking brakes properly engaging.
Maintenance Procedures Every 500 Hours or 3 Months

TIRE AND WHEEL ASSEMBLIES MAST AND CARRIAGE
Inspect the wheel rim for rust and cracks. Do not
weld a cracked wheel rim or straighten a bent rim.
WARNING
Welding, heating, or bending a wheel rim can weaken Use special safety precautions when working
its capacity. Always replace damaged tires or wheel on or near the mast or carriage. See Safety Pro-
rims immediately. Do not operate a truck with a bro- cedures When Working Near Mast.
ken stud or missing lug nuts. Tighten the fasteners
Do not work under a raised carriage. Lower
in a crisscross pattern to the correct torque value.
the carriage or install a safety chain to prevent
See Figure 10.
the carriage from lowering when performing
When the wheels have been removed and installed, maintenance on the mast and lift chains.
check all wheel nuts after 2 to 5 hours of operation.
Cleaning solvents can be flammable and toxic
Tighten the nuts in a cross pattern to the correct
torque value. When the nuts stay tight after an
cleaning solvents, always follow the recom-
8-hour check, the interval for checking the torque
mendations of the manufacturer.
can be extended to every 500 hours or 3 months.
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 lu-
brication 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 of
the mast and carriage as shown in Figure 11 and
Figure 12. Apply lubricant only to the indicated
surfaces.
NOTE: The load rollers and sheaves have sealed bear-

ings that do not need additional lubrication.
2. Lubricate the mast pivots with multipurpose

Figure 10. Torquing Pattern
grease at the grease fittings on the pivot pins.
16
8000 SRM 1079 Maintenance Procedures Every 500 Hours or 3 Months
A. UPPER LOAD ROLLERS

B. LOWER LOAD ROLLERS
1. LUBRICATE STRIP BEARINGS SURFACES
2. LUBRICATE SURFACES WHERE LOAD
ROLLERS TRAVEL
3. LOAD ROLLER
Figure 11. Mast Lubrication
BATTERY
In addition to normal charging, the battery requires
an equalizing charge periodically. This is a charge at
a low rate to balance the charge of all the cells. The
equalizing charge is normally given approximately
once a month, but no more than once a week. Charge
the battery at a slow rate for three to six hours in
addition to the normal charging cycle. The most ac-
curate specific gravity measurements for a charged
battery will be after an equalizing charge. Check the
specific gravity of each cell. If the specific gravity dif-
ference is more than 0.020 between cells of the bat-
tery after an equalization charge, there may be a de-
fective cell. Consult your battery dealer if you sus-
pect a defective cell or other battery damage.
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 12. Two-Stage Mast With Full Free Lift
17
PARKING BRAKES
The parking brake consists of two identical
spring-applied/electrically-released brakes mounted
directly to the drive motors. The controller breaks
the power supply to the brake coils, engaging the
parking brake when the truck is stopped. Pressing
the emergency disconnect button will apply the
parking brake immediately in any mode of opera-
tion. The parking brake should be checked to ensure
proper operation. First, check the air gap between
the brake coil and the pressure plate using a feeler
gauge:
1. Raise the mast so that the transaxle and brake

assemblies can be accessed. Install a safety chain
to the mast.

connect the battery. Block the lift truck wheels
to prevent unexpected movement.
3. Using a feeler gauge, measure the distance be-

tween the brake coil and the pressure plate on
each brake assembly. The measure should read
between 0.30 to 0.46 mm (0.011 to 0.018 in.). See
Figure 13.
4. If the air gap is larger than allowed, the friction

surfaces are excessively worn. An air gap that
is too small signifies damage to internal compo- 1. BRAKE COIL 3. PRESSURE PLATE
nents or foreign objects inside the brake. In ei- 2. AIR GAP 4. FEELER GAUGE
ther case, repair or replace the brake assembly.
Figure 13. Air Gap Measure
Refer to Brake System 1800 SRM 1076.
5. Test the lift truck to ensure that the parking

brake is performing to the proper specification.
This is accomplished by driving a lift truck up
a specified grade, stopping the truck using the
service brakes, and then releasing the service
brakes to check if the parking brakes can hold
the truck on the grade.
6. If the air gap is correct and the parking brake

cannot hold the truck on the grade, move the
truck to a safe, level location and clean the fric-
tion disks on each brake assembly using stan-
dard automotive brake cleaner:
1. BRK_RUN 1
a. Locate the parking brake connectors 2. BRK_RUN 2
3. BRK_TOWING
(BRK_RUN 1, BRK_RUN 2, and the 4. BRAKE DIODE
BRK_TOWING) beside the brake diode 5. MAIN WIRING HARNESS
on the main wiring harness. These items are
found near the front, right wheel well. See Figure 14. Brake Diode and Release Connectors
Figure 14.
18
b. If a charged battery is not installed in the f. Retest the parking brake for proper hold on
lift truck, use special tool - Auxiliary Bat- grade. If the parking brakes do not hold to
tery Connector (Hyster™ P/N 1564329) and specification, repair or replace the parking
an auxiliary 24-volt power supply to energize brake assemblies. Refer to Brake System
the brake override circuit: 1800 SRM 1076.
(1) Disconnect the BRK_RUN 1 and TRANSAXLE

BRK_RUN 2 connectors.
Each transaxle has its separate oil supply. See Fig-
(2) Connect the auxiliary battery connector ure 15. Make sure the lift truck is parked in a level
to the BRK_RUN 2 connector. area. Remove the oil fill plug to check the level of
the oil. The oil should be level with the bottom of the
(3) Connect the jumper wires to the 24-volt
hole. If it is necessary to add oil, add oil through the
auxiliary power source and listen for
fill plug hole until the oil is level with the bottom of
the parking brakes to release.
the hole. Replace the oil fill plug. Torque to 40 N•m
c. If a charged battery is installed in the lift (30 lbf ft).
truck, use the BRK_TOWING connector to
Check the oil level separately in each transaxle.
energize the brake override circuit:
(1) Disconnect the BRK_RUN 1 and

(2) Connect the BRK_TOWING and

(3) Pull the emergency disconnect switch

to the RUN position and listen for the
parking brakes to release.
d. Spray thoroughly between the pressure plate

and the mounting plate of the brake assem-
bly using standard automotive brake cleaner.
e. Return the brake connectors to the normal

operating mode and test the parking brakes
again:
1. OIL FILL PLUG
(1) Push the emergency disconnect switch 2. R. H. TRANSAXLE
3. TRACTION MOTOR
to the OFF position. 4. PARKING BRAKE
(2) Disconnect the BRK_TOWING and Figure 15. Transaxle Oil Level
(3) Reconnect the BRK_RUN 1 and

19
Maintenance Procedures Every 1000 Hours or 6 Months

LIFT CHAINS
WARNING
When working on or near the mast or carriage,
refer to Safety Procedures When Working Near
Mast in this section.
Do not work under a raised carriage. Lower

the carriage or use a safety chain to prevent
the carriage from lowering when doing main-
tenance on the mast and lift chains.
1. Lubricate the lift chains with SAE 20 or 30 en-

gine oil. For best results, 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 avail-
able, check the lift chains as shown in Figure 16.
If a chain scale is not available, measure 20 links Pitch Wear Limit
of chain. Measure from the center of a pin to the Total length of
The maximum
center of another pin 20 pitches away. Compare 20 links (pitch)
length of 20
the length with the chart in Figure 16. Replace of new chain
links.
the chain if the length of 20 links of the worn sec-
tion is more than the maximum wear limit. 12.7 mm 254.0 mm 261.6 mm
(0.50 in.) (10.0 in.) (10.3 in.)
HYDRAULIC BREATHER CAP 15.9 mm 317.5 mm 327.0 mm
(0.63 in.) (12.5 in.) (12.9 in.)
The hydraulic breather cap allows air to enter the 19.1 mm 381.0 mm 392.4 mm
hydraulic tank when the hydraulic oil is pumped (0.75 in.) (15.0 in.) (15.4 in.)
out to the cylinders. When the hydraulic oil returns 25.4 mm 508.0 mm 523.3 mm
to the tank, air is expelled through the hydraulic (1.00 in.) (20.0 in.) (20.6 in.)
breather cap. A filter in the cap protects the hy- 31.8 mm 635.0 mm 654.1 mm
draulic system from particles of dirt and other (1.25 in.) (25.0 in.) (25.75 in.)
contaminants. If the filter becomes excessively 44.5 mm 889.0 mm 915.7 mm
dirty, air flow can be restricted, causing pressures (1.75 in.) (35.0 in.) (36.05 in.)
and vacuums to build inside the tank. If air flow 50.8 mm 1016.0 mm 1046.5 mm
becomes restricted through the hydraulic breather (2.00 in.) (40.0 in.) (41.2 in.)
cap, replace the assembly. Keep the hydraulic tank
area clean and do not overfill the hydraulic tank. NOTE: THE INSTRUCTIONS FOR MEASURING
CHAIN WEAR ARE SHOWN ON THE CHAIN WEAR
SCALE.
1. CHAIN WEAR SCALE
Figure 16. Lift Chains Check
20
MASTER CYLINDER brushes must be replaced before they damage the

surface of the commutator.
WARNING 2. Move the brush spring and remove a brush from
Loss of fluid from the master cylinder indicates the brush holder. When the brush wears to
a leak. This condition can cause brake failure, within 1.5 mm (0.60 in.) of where the brush wire
resulting in material damage or personal in- joins the brush, the brush must be replaced.
jury. Repair the brake system before return-
ing to service if a leak is suspected. Drain and The brush spring makes a contact when the
flush the service brake system when contami- brush is worn to the length where it must be
nated by dirt, water, or other unapproved flu- replaced. A status code will appear on the LCD
ids. screen as an indication that the brushes must be
replaced.
The service brake system is a self-contained sys-
tem filled with hydraulic oil and does not require 3. Inspect the brush holders for burns or damage.
frequent service. However, normal operation does Make sure the brush holder is fastened tightly to
use a small amount of hydraulic fluid and must be the mounts at the end of the motor. Make sure
checked and refilled at the 1000-hr/6-month interval. the brushes will move freely and smoothly in the
A float switch inside the master cylinder reservoir brush holders.
activates an indicator light on the display panel
if the hydraulic oil drops below the minimum safe 4. Check the brush springs for damage from heat
level between checks, as in the case of a leak. The and corrosion. Replace any damaged brush
reservoir, mounted on top of the master cylinder, springs.
stores a small amount of hydraulic oil to compensate
See the service manual section DC Motor Mainte-
for normal loss. Remove the floor plates. Locate
nance 620 SRM 294 for additional information to in-
the master cylinder assembly near the brake pedal.
spect the commutator and brushes.
Remove the reservoir cap and fill the reservoir to
the full mark with hydraulic oil. See Maintenance
Schedule in this section. Reinstall the reservoir cap
Contactors
and check for leaks. If there is a leak or if the fluid
level has dropped below the minimum safe level, WARNING
the system may need to be bled before returning to Disconnect the battery and discharge the ca-
service. See Brake System 1800 SRM 1076. pacitors when working in the electrical com-
partment.
ELECTRICAL INSPECTION
WARNING
Hydraulic Motor Brushes
DO NOT file or lubricate the contacts. This may
The hydraulic motor is the only DC motor used on cause the contacts to stick, resulting in loss of
this truck. Hence, it is the only motor which has control and damage to property or personal in-
brushes which must be checked periodically and jury.
changed as required. If the motor brushes wear
below the minimum safe length during operation, a Inspect the contacts inside the contactors. Discon-
status code will appear on the LCD screen of the dis- nect the battery and discharge the capacitors. Re-
play panel to alert the operator. However, inspecting move the contactors from the electrical compartment
the brushes is necessary to prevent brush-related and disassemble. The contacts are made of a special
failures during operation. Repairing the brushes is silver alloy. The contacts will tarnish (appear black
convenient during the 1000-hr/6-month checks when and rough) over time. This condition occurs with nor-
the truck is not scheduled to be in service. mal operation of the lift truck and requires no ser-
vice. Cleaning is not necessary. Check for grooves,
1. Visually inspect the commutator and brushes. pits, and weld mark on the contacts. Damaged con-
Make sure the surface of the commutator is good tacts cannot be repaired and must be replaced. Al-
and the motor operates normally. Worn motor ways replace the contacts in sets.
21
Directional Speed Control TRANSAXLE, OIL CHANGE

The directional speed control lever is located on the
left side of the steering column on standard models. WARNING
It is attached to linkage inside the steering column Oil is hot at normal operating temperatures.
through a notch in the steering column covers. Re- Be careful when draining oil.
move the steering column covers. See Steering
System 1600 SRM 1075, Steering Wheel and Col- CAUTION
umn Assembly. Inspect the linkage and directional
control switches for damage and excessive wear.
Lubricate the linkage using silicone spray lubricant
and work the directional control lever back and NOTE: Operate the lift truck for 5 minutes or until
forth to ensure complete coverage. Foot-controlled the transaxle is warm to the touch. Oil is thick and
directional switches mounted to the top of the ac- will drain easier and more thoroughly when it is
celerator pedal are available as an option. These warm. Each transaxle uses separate, self-contained
models do not utilize a lever on the steering column. oil supplies. The oil in the transaxle should be
See Figure 17. changed every 2000 hours or yearly.
1. Raise and safety chain the mast to access the

transaxle assemblies. See Safety Procedures
When Working Near Mast. Disconnect the bat-
tery and block the wheels to prevent unexpected
movement.
2. Place a drip pan with at least a 3.8 liter (1 gal)

capacity under each transaxle.
3. Remove the fill and drain plugs on each

transaxle. See Figure 18 and Figure 19.
1. DIRECTIONAL CONTROL LEVER

2. DIRECTIONAL CONTROL SWITCHES
3. WIRING HARNESSES AND CONNECTORS
Figure 17. Directional Control Assembly
The accelerator is located on the floor of the opera-

tor’s compartment. Remove the floormat and floor
plates and lubricate the accelerator pedal pivots us-
ing silicone spray lubricant and work the pedal back
and forth to ensure complete coverage. 1. OIL FILL PLUG
2. R.H. TRANSAXLE
3. TRACTION MOTOR
4. PARKING BRAKE
Figure 18. Transaxle Oil Fill Plug
22
8000 SRM 1079 Maintenance Procedures Every 2000 Hours or Yearly
4. After both transaxles have drained completely,

replace the drain plugs and remove the drip
pans. Torque drain plugs to 40 N•m (30 lbf ft).
5. Fill the transaxles with oil until level with the

bottom of the fill holes.
6. Install the oil fill plugs. Torque oil fill plugs to

40 N•m (30 lbf ft).
1. BRAKE BLEED VALVE

2. TRANSAXLE HOUSING
3. DRAIN PLUG
Figure 19. Transaxle Drain Plug
Maintenance Procedures Every 2000 Hours or Yearly

STEERING
The steering actuator is mounted to the rear of
the frame below the counterweight. The steering
tire and wheel assemblies and the actuator sup-
port much of the weight of the battery, frame, and
counterweight. The action of steering pushes and
pulls on the actuator in various directions. The
hardware attaching the actuator to the frame should
be checked to ensure proper torques every 2000
hours or yearly. Position the lift truck on blocks
with the steering tire and wheel assemblies raised
off the floor. Check that the steering actuator is
securely mounted to the frame by tightening the
attaching hardware to the proper torque. If there is
play between these components, remove the nuts,
washers, and mounting capscrews from the actuator
one at a time. Apply Loctite™ 271 to the threads of
each mounting capscrew and reinstall. The proper
torque for the steering actuator attaching hardware
is 290 N•m (215 lbf ft). See Figure 20.
1. ATTACHING HARDWARE
2. STEERING ACTUATOR
3. FRAME
Figure 20. Steering Actuator Mounting
23
Maintenance Procedures Every 2000 Hours or Yearly 8000 SRM 1079
HYDRAULIC 6. Clean the breather cap/dipstick. See Figure 21.
Hydraulic Oil Filter, Change Hydraulic Oil Strainer, Check

Replace the filter element after the first 50 hours of Remove the breather cap/dipstick from the top of the
service and every 2000 hours or yearly after that. See hydraulic tank. Visually inspect the hydraulic oil
Figure 21. strainer located inside the fill hole. The screen must
be kept clean in order to strain the new oil added to
1. Loosen the four capscrews (1) securing cover to the system. If dirt, trash, rust, or sludge is present,
the hydraulic oil filter housing located on top of clean the strainer. If the strainer cannot be cleaned
the hydraulic oil tank. or is broken, it should be replaced. See Figure 21.
2. Press down on the cover while removing the cap- 1. Remove the breather cap/dipstick.
screws to depress the element retainer spring.
2. Remove the three screws and lockwashers (3) re-
taining the strainer assembly to the hydraulic
tank.
3. Remove the strainer assembly from the tank.
4. Clean or replace the strainer. Check the gaskets

for damage. Replace if necessary.
5. Install the housing and strainer assembly to the

tank.
6. Install the three screws and lockwashers (3) re-

taining the hydraulic oil strainer and gaskets to
the hydraulic tank.
Hydraulic Oil, Change
1. CAPSCREW WARNING
2. BREATHER CAP/DIPSTICK The hydraulic oil is hot at normal operating
3. SCREW AND LOCKWASHER temperatures. Be careful when draining hot
4. STRAINER ASSEMBLY oil.
5. CAPSCREW, LOCKWASHER, AND WASHER
6. STEERING SUPPLY
7. HYDRAULIC TANK CAUTION
8. GROUND WIRE
Figure 21. Hydraulic Tank Assembly cal environmental regulations.
3. Remove the cover and spring from housing. The hydraulic oil should be changed every 2000
Check O-ring seal on the cover for cracks or hours or yearly. When the hydraulic system compo-
deterioration. Replace if damaged. nents such as the pump or steering control unit have
been damaged or the oil has otherwise been con-
4. Remove element from housing and replace with taminated, the hydraulic system should be drained,
a new element. flushed, and refilled with new hydraulic oil.
5. Install the cover and spring to the housing using 1. Put the lift truck on a level surface and lower the
four capscrews. Press the cover down onto the mast.
housing while installing the capscrews. Torque
capscrews to 6 N•m (53 lbf in).
24
8000 SRM 1079 General Repairs
2. Turn the key switch to the OFF position and dis- 8. Coil hose and secure below the floor plates using
connect the battery. Block the wheels to prevent a new wire tie.
unexpected movement.
NOTE: Check the hydraulic oil level by wiping the
3. Remove the floormat and floor plates. dipstick clean and install the breather cap/dipstick
on to the tank. Remove again and check the oil level
4. Remove the breather cap/dipstick to allow faster on the dipstick.
draining.
9. Fill the hydraulic tank to the proper level with
5. Locate the hydraulic tank drain hose. Clip the new hydraulic oil. DO NOT overfill the hy-
wire tie retaining the hose using wire cutters and draulic tank.
route it under the side of the frame to the outside
of the lift truck. Position the hose to drain into a 10. Install the breather cap/dipstick.
container suitable for storing used hydraulic oil
with a minimum capacity of 19 liter (5 gal). 11. Operate the lift pump for 1 to 2 minutes to purge
air from the hydraulic system; then recheck the
6. Remove the hose clamp and drain plug from the hydraulic oil level.
end of the hydraulic tank drain hose to drain the
hydraulic oil. 12. Install the floormat and floor plates.
7. When the oil has drained, reinstall the drain plug

into the hose and secure with hose clamp.
General Repairs
WELDING REPAIRS may occur without odor warning. When per-
forming work, utilize good industrial hygiene
WARNING practices, including removal of all paint (prime
and finish coats) to the metal around the area
Remove the battery and disconnect the battery
to be welded. Use local ventilation, and/or
connector before welding. Welding can cause a
supplied-air respiratory protection.
fire and/or an explosion. Make sure there is no
fuel, oil, or grease near the weld area. Make
sure the area is well ventilated. CAUTION
Always disconnect the battery connector to
WARNING prevent damage to electrical components
Forklift truck frames and components may when welding. Connect the welding ground
have polyurethane paint. Welding, burning, or clamp as close to the weld area as possible to
other heat sufficient to cause thermal decom- prevent welding current from straying.
position of the paint may release isocyanates.
Only properly trained, authorized technicians should
These chemicals are allergic sensitizers to
perform welding repairs.
skin and respiratory tract and overexposure
25
Lift and Tilt System Leak Check 8000 SRM 1079
PAINTING INSTRUCTIONS Tires

Chains and Hoses
WARNING Battery Connector
Key Switch
Always use solvents and paints in an area with
Cylinder Rods
adequate ventilation. Do not use solvents or
All Plastic Covers
paints near heat, fire, or electrical equipment
Pumps and Motors
that can make sparks. Follow the manufac-
Control Valve
turer’s instructions and cautions.
Wiring Harnesses or Connectors
CAUTION
DO NOT put tape on cylinder rods to protect
CAUTION
from paint. Use a thick layer of multipurpose Do not paint the pads, plastic covers or knobs,
grease to protect cylinder rods. Cylinders can cables, labels, information plates, or controls.
be damaged if operated with tape on the cylin- Paint can cause some assemblies to operate in-
der rod. correctly.
1. Clean the surface to be painted. Use a solvent NOTE: Use colors approved by Hyster Company.
on surfaces to be painted to remove grease and
4. Paint the surfaces. Use the proper paint from
oil before sanding. DO NOT use solvent to clean
your local Hyster lift trucks dealer. Follow the
new paint. Make sure all oil and grease is re-
directions on the container. Allow the paint to
moved.
dry according to the manufacturer’s directions.
2. Use sandpaper to remove the top surface of
paint and rust from the metal. All metal sur- WARNING
faces where the paint is removed to the bare Make sure ALL safety labels are installed.
metal must be primed. Apply primer BEFORE
applying the paint. 5. Install the safety labels and decals in the correct
locations on the lift truck. Safety labels and de-
3. Protect all surfaces that will not be painted. cals are installed on the lift truck to identify the
DO NOT paint: lift truck and its specifications and to give in-
Pedal Pads formation about possible hazards. It is impor-
Lever Knobs tant that ALL decals and safety labels are in-
Instrument Panel stalled on the lift truck and can be easily read.
Steering Wheel See Frame 100 SRM 1073 for proper label place-
Labels and Information Plates ment.
Seat Assembly and Rails
Information Case
Lift and Tilt System Leak Check

LIFT SYSTEM Do not try to find hydraulic leaks by putting
hands on pressurized hydraulic components.
WARNING Hydraulic oil can be injected into the body by
pressure, resulting in serious injury.
Special precaution is required when working
on or near the mast or carriage. See Safety Pro- During the test procedures for the hydraulic
cedures When Working Near Mast. system, fasten the load to the carriage with
chains to prevent it from falling. Keep all
Never allow anyone under a raised carriage.
personnel away from the lift truck during the
Do not put any part of your body in or through
tests.
the lift mechanism unless all parts of the mast
are completely lowered, the key is removed,
and the battery is disconnected.
26
8000 SRM 1079 Lift and Tilt System Leak Check
1. Place a capacity load (refer to the lift truck name Do not try to find hydraulic leaks by putting
plate) on the forks and secure with chains. Oper- hands on pressurized hydraulic components.
ate the hydraulic system by raising and lowering Hydraulic oil can be injected into the body by
the load several times. Lower the load, and tilt pressure, resulting in serious injury.
the mast forward and backward several times.
Visually inspect for leaks. During the test procedures for the hydraulic
system, fasten the load to the carriage with
2. Raise the carriage and the load 1 m (3 ft). If the chains to prevent it from falling. Keep all
carriage lowers slowly with the control valve in a personnel away from the lift truck during the
neutral position, there are leaks inside the hy- tests.
draulic system. The maximum speed that the
carriage is allowed to lower is 50 mm (2 in.) per 1. Place a capacity load on the forks and secure with
10 minutes when the hydraulic oil is 30 C (90 F). chains. Operate the hydraulic system by rais-
If the oil temperature is 70 C (160 F), the maxi- ing and lowering the load several times. Lower
mum speed that the carriage can lower is 150 mm the load, and tilt the mast forward and backward
(6 in.) per 10 minutes. several times. Visually inspect for leaks.
3. If the leak rate is greater than specifications, iso- 2. Slowly tilt the mast forward. If the mast contin-
late the lift cylinders to check for internal leaks. ues to slowly tilt forward when the control valve
Remove the load from the forks and install a gate is in a neutral position, there are leaks inside the
valve in the supply line between the main control hydraulic system. The maximum speed that the
valve and the mast. Put a capacity load on the mast is allowed to tilt forward when there are in-
forks again. Raise the carriage 1 m (3 ft). Close ternal leaks in the lift system is 13 mm (0.50 in.)
the gate valve. If the carriage or mast weldments per 10 minutes (measured at the tilt cylinder).
continue to lower, the seals in the lift cylinders This maximum speed is measured when the hy-
have leaks. draulic oil is 30 C (90 F). If the oil temperature
is 70 C (160 F), the maximum speed is 39 mm
4. If the carriage does not move, open the gate valve (1.5 in.) per 10 minutes.
and check for movement again. If the carriage
lowers when the valve is open, check for leaks 3. If the leak rate is greater than specifications, iso-
in the hydraulic lines or fittings. If there are no late the tilt cylinders to check for internal leaks.
external leaks, the main control valve might be Remove the load from the mast. Install a gate
damaged. Remove the load from the forks and valve between the port at the front of the tilt
troubleshoot the hydraulic system. cylinder and the hydraulic line. Secure the load
on the forks again and repeat Step 2. Close the
TILT SYSTEM gate valve. If the mast continues to tilt forward,
the cylinder seals are leaking.
WARNING 4. If the mast does not move, open the gate valve
Special precaution is required when working and check for movement again. If the mast
on or near the mast or carriage. See Safety Pro- moves forward when the gate valve is open,
cedures When Working Near Mast. check for leaks in the hydraulic lines or fittings.
If there are no external leaks, the main control
Never allow anyone under a raised carriage. valve might be damaged. Remove the load from
Do not put any part of your body in or through the forks and troubleshoot the hydraulic system.
the lift mechanism unless all parts of the mast
are completely lowered, the key is removed,
and the battery is disconnected.
27
Battery Maintenance
HOW TO CHARGE BATTERY interval based on usage. This practice will keep the
battery fully charged if the battery is not discharged
WARNING below the limit. Always use a hydrometer to check
the battery if the interval charge cycle is used. Fre-
If the lift truck was operated with a low battery,
quent charging of a battery that has a 2/3 or more
check all contactors for welded contacts before
charge can decrease battery life.
a charged battery is connected.
Make sure the key switch is in the OFF position

before connecting the battery.
The electrolyte in the battery contains acid

that can cause injury. If electrolyte is spilled,
use a solution of water and soda to neutralize
the acid. Flush areas where acid is spilled on
the skin with water. Acid in the eyes must be
continuously flushed with water for 15 min-
utes. 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
designated area. When the battery is being
charged, keep the vent caps clear. The battery
charger area must have adequate ventilation
to remove fumes. Keep the battery cover open
Specific Electrolyte Correction Correct
and the top of the battery clear. Disconnect
Gravity Temp. Points Value
the battery when cleaning and performing
Reading
maintenance.
1.210 31 C (88 F) +0.003 1.213
CAUTION 1.210 27 C (81 F) +0.001 1.211
Never connect the battery charger plug to 1.210 0.000 1.210
25 C (77 F)
the plug of the lift truck; you can damage the
electronic controller. Make sure the battery 1.210 18 C (64 F) 0.004 1.206
charger voltage is the correct voltage for the +0.001 or 0.001 for each 2 C from the 25 C base
battery. value.
Correct use of the hydrometer, and proper operation
of the battery charger, is important. See Figure 22. Figure 22. Battery Check
Follow the instructions of the charger manufacturer.
Never let the battery discharge below the minimum NOTE: Some batteries are maintenance free and do
value given by the battery manufacturer. A fully not require checking the electrolyte. Do not attempt
charged battery will have a specific gravity of 1.265 to check electrolyte in batteries with sealed cells.
to 1.310 at 25 C (77 F). Never charge a battery at a EQUALIZING CHARGE: This charge is at a low rate
rate that will raise the electrolyte temperature above and balances the charge in all of the cells. The equal-
49 C (120 F). Never let a battery stay discharged for izing charge is normally given approximately once a
long periods. month. It is a charge at a slow rate for 3 to 6 hours
NORMAL CHARGE: This is the charge that is nor- in addition to the regular charging cycle.
mally given to a battery that is discharged from nor-
mal service. Many users give this charge at a regular
28
Do NOT give an equalizing charge more than once 2. Release the hydraulic control cover, and raise the
a week. The most accurate specific gravity mea- hydraulic controls and the cover for access to the
surements for a charged battery will be after an hood latch. Disengage the hood latch and raise
equalizing charge. If the specific gravity difference the battery cover. The gas-filled, double-damp-
is more than 0.020 between cells of the battery after ened strut will help raise the hood and hold the
an equalizing charge, there may be a defective cell. battery cover in the open position for access to
Consult your battery dealer. the battery.
See the section Industrial Battery 2240 SRM 1 for 3. Move the connector and cables so they will not be
additional information on the charging and mainte- damaged when the battery is moved.
nance of a battery.
4. Use a spreader bar and overhead lifting device
NOTE: Many users have battery chargers that can to lift the battery from the lift truck. When a
follow a program to automatically charge a battery replacement battery is installed, make sure the
according to recommendations of the battery man- battery is the correct size and weight for the lift
ufacturer. Use the recommendations of the battery truck. See the Nameplate.
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.
Batteries are heavy. Use care to avoid injury.
The replacement battery must fit the battery

area correctly. Use spacers to prevent the bat-
tery from shifting inside the battery compart-
ment. Figure 23. Changing Battery
Make sure the weight of the replacement bat- BATTERY SIZE SPECIFICATIONS
tery is within the maximum and minimum
weights shown on the Nameplate. Batteries function as part of the lift truck’s counter-
weight system. Installing a battery that is too small
can leave the lift truck lacking sufficient weight to
WARNING counter the rated load. Refer to the nameplate when
Make sure the key switch is in the OFF position replacing a battery to verify the truck rating to en-
before connecting the battery. sure that the battery (and spacer if so equipped) is
of the proper size. See Capacities and Specifica-
1. Disconnect the battery. Move the steering wheel
tions 8000 SRM 1080 for exact battery specifications
to its top position. Move the seat backward to its
for your truck.
rear adjustment position. See Figure 23.
29
NOTES
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
30

CAPACITIES AND
SPECIFICATIONS
J1.6-2.0XMT (J30-40ZT) [J160]
PART NO. 1554636 8000 SRM 1080

SAFETY PRECAUTIONS

trucks.
nance section.
manual:
WARNING
CAUTION
Capacities and Specifications Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Hydraulic System............................................................................................................................................... 2
Steering System ................................................................................................................................................. 3
Tire Sizes ............................................................................................................................................................ 4
Torque Specifications ......................................................................................................................................... 5
Electrical ........................................................................................................................................................ 5
Steering System............................................................................................................................................. 5
Hydraulic System .......................................................................................................................................... 5
Manual Hydraulic Valve ............................................................................................................................... 5
Transaxle........................................................................................................................................................ 5
Transaxle Assembly ........................................................................................................................................... 6
Travel Speeds ..................................................................................................................................................... 7
Battery................................................................................................................................................................ 8
J1.6-2.0XMT (J30-40ZT) [J160]

"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
General
European
Model Wheel Base Grade Turning Radius Right Angle Aisle
Clearance Clearance 1
J1.6XMT 1290 mm (50.8 in.) 31% 1470 mm (57.9 in.) 2581 mm (101.6 in.)
1385 mm (54.5 in.) 29% 1565 mm (61.6 in.) 2676 mm (105.4 in.)
1495 mm (58.9 in.) 27% 1675 mm (65.9 in.) 2786 mm (109.6 in.)
1495 mm (58.9 in.) 27% 1675 mm (65.9 in.) 2786 mm (109.6 in.)
1
Equipped with two-stage mast and carrying a 762 mm (30 in.) long × 813 mm (32 in.) wide load.
U.S.
Model Wheel Base Grade Turning Radius Right Angle Aisle
Clearance Clearance 1
J30ZT 1290 mm (50.8 in.) 32% 1470 mm (57.9 in.) 2581 mm (101.6 in.)
1
Equipped with two-stage mast and carrying a 762 mm (30 in.) long × 813 mm (32 in.) wide load.
Specifications
Maximum Gross Vehicle Weight 5600 kg (12,346 lb)
Counterweight 670 kg (1477 lb)
Maximum Load 1815 kg (4000 lb)
Brake Drawbar Drag (BDBD) 1633 kg (3600 lb)
@125 lbs Pedal Effort
Brake Master Cylinder 10W Hydraulic Oil (API CC/SG and/or CD/SH)
(MIL-PRF-2104) 1
1
MIL-PRF-5606 performance oil required in freezer applications.
1
Hydraulic System 8000 SRM 1080
Hydraulic System
Hydraulic Pump
Displacement 17 cc/rev
Operating Temperature 0 to 80 C (32 to 176 F)
Filtration 10 Micron Nominal
Max Pressure 18.1 MPa (2611 psi)
Max Peak Pressure 20.6 MPa (2902 psi)
Inlet Pressure 0.200 to 0.490 bar ( 2.9 to 7.1 psi)
Hydraulic Lift Motor 36/48 Volt DC Motor
@ 36 Volts @ 48 Volts
Power 9 kW (12 hp) 12 kW (16 hp)
Speed 600-3000 rpm
Thermal Rating S3 = 15% S3 = 15%
Brush Wear LED indicator on Display Panel
Insulation Class "H"
Hydraulic System
Fluid Type 10W Hydraulic Oil (API CC/SG and/or CD/SH)(MIL-PRF-2104)
Main Relief Pressure 17.9 MPa (2600 psi)
(Manual Valve)
Main Relief Pressure 17.9 MPa (2600 psi)
(Electro-valve)
Secondary Relief Valve 13.8 MPa (2000 psi)
Tank Capacity 19 liter (5.0 gal)
(To Full Mark)
System Capacity 21.80 liter (5.75 gal)
2
8000 SRM 1080 Steering System
Steering System
System Specifications
Steering System
Normal Operating Temperature 49 to 60 C (120 to 140 F)
Fluid Type 10W Hydraulic Oil (API CC/SG and/or CD/SH)(MIL-PRF-2104)
(Drawn from Hydraulic Tank)
Steering Control Unit
Displacement 63 cm 3 /rev (3.84 cu in. 3 /rev)
Relief Valve 1 75.8 bar (1100 psi)
Steering Pump Motor
Voltage 36 Volts DC 48 Volts DC

Speed 2100 rpm 1850 rpm
Output 0.80 kW (1.07 hp) 0.80 kW (1.07 hp)
Steering Gear Pump
Displacement 4.23 cm 3 /rev (.258 in. 3 /rev)
Relief Valve Not Applicable
Steering Actuator
Max Torque 570 N•m (420 lbf ft)
Oil Pressure (Max Torque) 61 bar (885 psi)
Range of Motion 185
1
Refers to anti-kickback check valve. Anti-cavitation check valve is not adjustable.
3
Tire Sizes 8000 SRM 1080
Tire Sizes
European
Model Drive
Tire Wheel
Size Description Quantity Size Description Quantity

J1.6-1.8XMT 18×7-8 Solid Pneumatic 2 4.33R-8 Locking Ring Wheel 2
18×7-12.1 Solid Cushion 2 Cast Wheel 2
J2.0XMT 200/50-10 Solid Pneumatic 2 6.50F-10 Locking Ring Wheel 2
European
Model Steer
Tires Wheel
J1.6-1.8- 15×4.5-8 Solid Pneumatic 2 4.33R-8 Locking Ring Wheel 2
2.0XMT
U.S.
Model Drive
Tire Wheel

J30-35ZT 18×7-8 Solid Pneumatic 2 4.33R-8 Locking Ring Wheel 2
J40ZT 200/50-10 Solid Pneumatic 2 6.50F-10 Locking Ring Wheel 2
U.S.
Model Steer
Tires Wheel
J30-35-40ZT 15×4.5-8 Solid 2 4.33R-8 Locking Ring 2
Pneumatic Wheel
15×4×11.2 Solid Cushion 2 Cast Wheel 2
4
Torque Specifications
ELECTRICAL Pump Motor to Motor Bracket (4 Places)
48 N•m (35 lbf ft)
Controller Terminals (All Locations)
13 N•m (115 lbf in) Motor Bracket to Frame (4 Places)
48 N•m (35 lbf ft)
Steering Potentiometer Jam Nut
1.25 N•m (11 lbf in) Lift Pump to Motor (2 Places)
61 N•m (45 lbf ft)
Accelerator Position Sensor
2.2 N•m (19 lbf in) Lift Pump Hydraulic Fittings (2 Places)
80 N•m (59 lbf ft)
STEERING SYSTEM (Maximum)
Steer Pump Motor to Lower Bracket (2 Auxiliary Hose Mounting Plate (2 Places)
Places) (Loctite™ 242) 61 N•m (45 lbf ft)
15 N•m (133 lbf in)
MANUAL HYDRAULIC VALVE
Steer Pump Motor to Upper Bracket (2
Places) (Loctite™ 242) Relief Valve Retaining Nuts (1 Each)
3 N•m (26 lbf in) 5 N•m (44 lbf in)
Steer Pump Motor to Pump (2 Places) Section Retaining Stud Nuts (Front) (1 Place)
(Loctite™ 242) 24 N•m (18 lbf ft)
15 N•m (133 lbf in)
Section Retaining Stud Nuts (Rear) (2 Places)
Steering Actuator to Frame (3 Places) 10 N•m (89 lbf in)
290 N•m (214 lbf ft)
TRANSAXLE
Steering Control Unit Fittings (4 Places)
40 N•m (30 lbf ft) Transaxle to Frame (5 Each) (Loctite™ 271)
220 N•m (162 lbf ft)
Steering Control Unit Capscrews (4 Places)
40 N•m (30 lbf ft) Drive Motor to Transaxle (4 Each)
(Loctite™ 271)
Steering Encoder and Horn Contac- 48 N•m (35 lbf ft)
tor (4 Places)
.5 N•m (4 lbf in) Wheel Lugs (5 Each)
170 N•m (125 lbf ft)
Steering Gear Pump Inlet Fitting (1 Place)
80 N•m (59 lbf ft) Trunnion Caps (2 Each) (Loctite™ 290)
35 N•m (26 lbf ft)
Steering Gear Pump Outlet Fitting (1 Place)
56 N•m (41 lbf ft) Oil Fill Plug (1 Each)
40 N•m (30 lbf ft)
Steering Gear Pump Plug
18 N•m (13 lbf ft) Oil Drain Plug (1 Each)
40 N•m (30 lbf ft)
HYDRAULIC SYSTEM
Breather (1 Each)
Filter Housing to Tank (2 Places) 10 N•m (89 lbf in)
8 N•m (72 lbf in)
Brake Bleed Valve (1 Each)
Filter Housing Cover (4 Places) 10 N•m (89 lbf in)
6 N•m (53 lbf in)
5
Brake Passage Plugs (2 Each) Wheel Hub Capscrews (1 Each)

10 N•m (89 lbf in) 280 N•m (207 lbf ft)
Transaxle Assembly
Function Specification
Traction Motor 36 Volts AC 48 Volts AC
Power 4.8 kW (6.43 hp) 5.0 kW (6.70 hp)
Stator Resistance 6.10 ±0.10 ohms 10.00 ±0.10 ohms
Gear Ratio 25.6:1
Drive Wheel Load 1080 kg (2380 lb)
Fluid Type Hydraulic Oil (JDM J20)
Fluid Capacity 350 cc (21.4 in. 3 )
0.35 liter (0.37 qt)
Brake Specifications
Torque at Axle 1795 N•m (1324 lbf ft)
Hold on Grade (Loaded) 16% Grade
Hold on Grade (No Load) 25% Grade
6
8000 SRM 1080 Travel Speeds
Travel Speeds
European
Model Voltage Extended Maximum Travel Speed
Shift
No Load Full Load
kph mph kph mph
J1.6XMT 48 ON 14.3 8.9 13.0 8.1
OFF 14.3 8.9 14.1 8.8
J1.8XMT 48 ON 14.3 8.9 12.8 8.0
OFF 14.3 8.9 14.0 8.7
J2.0XMT 48 ON 14.3 8.9 11.9 7.4
OFF 14.3 8.9 13.8 8.6
U.S.
Model Voltage Extended Maximum Travel Speed
Shift
No Load Full Load
kph mph kph mph
J30ZT 36 ON 13.2 8.2 13.0 8.1
OFF 14.3 8.9 14.0 8.7
48 ON 14.3 8.9 12.7 7.9
OFF 14.3 8.9 14.1 8.8
J35ZT 36 ON 13.2 8.2 13.0 8.1
OFF 14.3 8.9 14.0 8.7
48 ON 14.3 8.9 12.4 7.7
OFF 14.3 8.9 14.0 8.7
J40ZT 36 ON 13.2 8.2 13.0 8.1
OFF 14.3 8.9 14.0 8.7
48 ON 14.3 8.9 11.9 7.4
OFF 14.3 8.9 13.8 8.6
7
Battery 8000 SRM 1080
Battery
Figure 1. Battery Dimensions
Battery Compartment Dimensions (European)

Model Wheel Base Width (X) Length (Y) Height (Z)
BS Battery DIN Battery 1
J1.6XMT 1290 mm 990 mm 546 mm 673 mm 647 mm
(50.8 in.) (39 in.) (21.5 in.) (26.5 in.) (25.5 in.)
1385 mm 990 mm 641 mm 673 mm 647 mm
(54.5 in.) (39 in.) (25.2 in.) (26.5 in.) (25.5 in.)
J1.8XMT 1385 mm 990 mm 641 mm 673 mm 647 mm
(54.5 in.) (39 in.) (25.2 in.) (26.5 in.) (25.5 in.)
1495 mm 990 mm 751 mm 673 mm 647 mm
(58.9 in.) (39 in.) (29.6 in.) (26.5 in.) (25.5 in.)
J2.0XMT 1385 mm 990 mm 641 mm 673 mm 647 mm
(54.5 in.) (39 in.) (25.2 in.) (26.5 in.) (25.5 in.)
1495 mm 990 mm 751 mm 673 mm 647 mm
(58.9 in.) (39 in.) (29.6 in.) (26.5 in.) (25.5 in.)
1
Measurement with acid plate and appropriate counterweight/spacer installed.
8
8000 SRM 1080 Battery
Battery Compartment Dimensions (U.S.)

Model Wheel Base Width (X) Length (Y) Height (Z)
High Battery Low Battery 1
J30ZT 1290 mm 990 mm 546 mm 663 mm 587 mm
(50.8 in.) (39 in.) (21.5 in.) (26.10 in.) (23.12 in.)
J35ZT 1385 mm 990 mm 641 mm 663 mm 587 mm
(54.5 in.) (39 in.) (25.2 in.) (26.10 in.) (23.12 in.)
J40ZT 1385 mm 990 mm 641 mm 663 mm 587 mm
(54.5 in.) (39 in.) (25.2 in.) (26.10 in.) (23.12 in.)
1
Measurement with acid plate and appropriate counterweight/spacer installed.
Battery Discharge Rate (European.) 1

Model Wheel Base Type Max Amp Hours Max kW Hours
48 V 48 V
J1.6XMT 1290 mm (50.8 in.) DIN 400 18.2
BS 602 28.9
1385 mm (54.5 in.) DIN 500 24.0
BS 630 30.2
J1.8XMT 1385 mm (54.5 in.) DIN 500 23.5
BS 720 34.5
1495 mm (58.9 in.) DIN 600 28.8
BS 720 34.5
J2.0XMT 1385 mm (54.5 in.) DIN 500 23.5
BS 720 34.5
1495 mm (58.9 in.) DIN 600 28.8
BS 720 34.5
1
Calculated using 6-hour rate.
Battery Discharge Rate (U.S.) 1

Model Max Amp Hours Max kW Hours
36 V 48 V 36 V 48 V
J30ZT 880 660 30.6 30.5
J35ZT 1100 770 38.2 35.8
J40ZT 1100 770 38.2 35.8
1
Calculated using 6-hour rate.
9
Battery Specifications (European)

Model Type (48 Wheel Weight Width (X) Length (Y) Height (Z)
V) Base
J1.6XMT DIN 1 1290 mm MIN 673 kg 826 mm 533 mm 627 mm
(50.8 in.) (1484 lb) (32.5 in.) (21.0 in.) (24.7 in.)
MAX
MAX 743 kg 836 mm 543 mm
(1638 lb) (32.9 in.) (21.4 in.)
1385 mm MIN 813 kg 826 mm 627 mm 627 mm
(54.5 in.) (1792 lb) (32.5 in.) (24.7 in.) (24.7 in.)
MAX
MAX 899 kg 836 mm 638 mm
(1982 lb) (32.9 in.) (25.1 in.)
BS 1290 mm MIN 800 kg 977 mm 533 mm 670 mm
(50.8 in.) (1764 lb) (38.5 in.) (21.0 in.) (26.4 in.)
MAX
MAX 1100 kg 987 mm 543 mm
(2425 lb) (38.9 in.) (21.4 in.)
1385 mm MIN 800 kg 977 mm 628 mm 670 mm
(54.5 in.) (1764 lb) (38.5 in.) (24.7 in.) (26.4 in.)
MAX
MAX 1200 kg 987 mm 638 mm
(2646 lb) (38.9 in.) (25.1 in.)
(54.5 in.) (1792 lb) (32.5 in.) (24.7 in.) (24.7 in.)
MAX
MAX 899 kg 836 mm 638 mm
(1982 lb) (32.9 in.) (25.1 in.)
1495 mm MIN 962 kg 826 mm 738 mm 627 mm
(58.9 in.) (2121 lb) (32.5 in.) (29.1 in.) (24.7 in.)
MAX
MAX 1064 kg 836 mm 748 mm
(2346 lb) (32.9 in.) (29.4 in.)
(54.5 in.) (2205 lb) (38.5 in.) (24.7 in.) (26.4 in.)
MAX
MAX 1200 kg 987 mm 638 mm
(2646 lb) (38.9 in.) (25.1 in.)
1495 mm MIN 1000 kg 977 mm 738 mm 670 mm
(58.9 in.) (2205 lb) (38.5 in.) (29.1 in.) (26.4 in.)
MAX
MAX 1300 kg 987 mm 748 mm
(2866 lb) (38.9 in.) (29.4 in.)
1
Used with acid plate and appropriate counterweight/spacer installed.
10
8000 SRM 1080 Battery
Battery Specifications (European)

Model Type (48 Wheel Weight Width (X) Length (Y) Height (Z)
V) Base
(54.5 in.) (1792 lb) (32.5 in.) (24.7 in.) (24.7 in.)
MAX
MAX 899 kg 836 mm 638 mm
(1982 lb) (32.9 in.) (25.1 in.)
1495 mm MIN 962 kg 826 mm 738 mm 670 mm
(58.9 in.) (2121 lb) (32.5 in.) (29.1 in.) (26.4 in.)
MAX
MAX 1064 kg 836 mm 748 mm
(2346 lb) (32.9 in.) (29.4 in.)
(54.5 in.) (2701 lb) (38.5 in.) (24.7 in.) (26.4 in.)
MAX
MAX 1300 kg 987 mm 638 mm
(2866 lb) (38.9 in.) (25.1 in.)
1495 mm MIN 1000 kg 977 mm 738 mm 627 mm
(58.9 in.) (2205 lb) (38.5 in.) (29.1 in.) (24.7 in.)
MAX
MAX 1300 kg 987 mm 748 mm
(2866 lb) (38.9 in.) (29.4 in.)
1
Battery Specifications (U.S.)

Model Wheel Type Weight (approximate) Width (X) Length Height (Z)
Base (36/48 V) (Y)
J30ZT 1290 mm Low 1 MIN 775 kg 970 mm 508 mm 579 mm
(50.8 in.) (1700 lb) (38.2 in.) (20.0 in.) (22.8 in.)
MAX 1000 kg 986 mm 538 mm
(2200 lb) (38.8 in.) (21.2 in.)
High MIN 910 kg 970 mm 508 mm 655 mm
(2000 lb) (38.2 in.) (20.0 in.) (25.8 in.)
MAX 1135 kg 986 mm 538 mm
(2500 lb) (38.8 in.) (21.2 in.)
(54.5 in.) (2100 lb) (38.4 in.) (23.5 in.) (22.8 in.)
MAX 1090 kg 986 mm 635 mm
(2400 lb) (38.8 in.) (25.0 in.)
(2500 lb) (38.4 in.) (23.5 in.) (25.8 in.)
MAX 1270 kg 986 mm 635 mm
(2800 lb) (38.8 in.) (25.0 in.)
11
Battery Specifications (U.S.)

Model Wheel Type Weight (approximate) Width (X) Length Height (Z)
Base (36/48 V) (Y)
(54.5 in.) (2100 lb) (38.4 in.) (23.5 in.) (22.8 in.)
MAX 1090 kg 986 mm 635 mm
(2400 lb) (38.8 in.) (25.0 in.)
(2500 lb) (38.4 in.) (23.5 in.) (25.8 in.)
MAX 1270 kg 986 mm 635 mm
(2800 lb) (38.8 in.) (25.0 in.)
1
12
8000 SRM 1080 5/04 (4/04)(3/04) Printed in United Kingdom

DIAGRAMS
J1.6-2.0XMT (J30-40ZT) [J160]
PART NO. 1554637 8000 SRM 1081

SAFETY PRECAUTIONS

trucks.
nance section.
manual:
WARNING
CAUTION
Diagrams Table of Contents
TABLE OF CONTENTS
J1.6-2.0XMT (J30-40ZT).................................................................................................................................... 1
Figure 1. Wiring Schematic ...................................................................................................................... 1
Figure 10. Wiring Schematic .................................................................................................................... 10
Figure 12. Wiring Diagram ...................................................................................................................... 12
Figure 24. Hydraulic Schematic............................................................................................................... 24
Figure 25. Hydraulic Schematic............................................................................................................... 25
J1.6-2.0XMT (J30-40ZT) [J160]

"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
8000 SRM 1081 J1.6-2.0XMT (J30-40ZT)
Figure 1. Wiring Schematic
1
J1.6-2.0XMT (J30-40ZT) 8000 SRM 1081
2
8000 SRM 1081 J1.6-2.0XMT (J30-40ZT)
3
J1.6-2.0XMT (J30-40ZT) 8000 SRM 1081
4
8000 SRM 1081 J1.6-2.0XMT (J30-40ZT)
5
J1.6-2.0XMT (J30-40ZT) 8000 SRM 1081
6
8000 SRM 1081 J1.6-2.0XMT (J30-40ZT)
7
J1.6-2.0XMT (J30-40ZT) 8000 SRM 1081
8
8000 SRM 1081 J1.6-2.0XMT (J30-40ZT)
9
J1.6-2.0XMT (J30-40ZT) 8000 SRM 1081
10
8000 SRM 1081 J1.6-2.0XMT (J30-40ZT)
11
J1.6-2.0XMT (J30-40ZT) 8000 SRM 1081
Figure 12. Wiring Diagram
12
8000 SRM 1081 J1.6-2.0XMT (J30-40ZT)
13
J1.6-2.0XMT (J30-40ZT) 8000 SRM 1081
14
8000 SRM 1081 J1.6-2.0XMT (J30-40ZT)
15
J1.6-2.0XMT (J30-40ZT) 8000 SRM 1081
16
8000 SRM 1081 J1.6-2.0XMT (J30-40ZT)
17
J1.6-2.0XMT (J30-40ZT) 8000 SRM 1081
18
8000 SRM 1081 J1.6-2.0XMT (J30-40ZT)
19
J1.6-2.0XMT (J30-40ZT) 8000 SRM 1081
20
8000 SRM 1081 J1.6-2.0XMT (J30-40ZT)
21
J1.6-2.0XMT (J30-40ZT) 8000 SRM 1081
22
8000 SRM 1081 J1.6-2.0XMT (J30-40ZT)
23
J1.6-2.0XMT (J30-40ZT) 8000 SRM 1081
Figure 24. Hydraulic Schematic
24
8000 SRM 1081 J1.6-2.0XMT (J30-40ZT)
Figure 25. Hydraulic Schematic
25
NOTES
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
26

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FRAME

J1.6-2.0XMT (J30-40ZT) [J160]

PART NO. 1554626 100 SRM 1073

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

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

This section is for the following models:

J1.6-2.0XMT (J30-40ZT) [J160]

©2004 HYSTER COMPANY i

Each model of lift truck has a cast-iron counter-

The hydraulic pump and motor, steering pump and

The hydraulic control valve is fastened to the front

DISCHARGING THE CAPACITORS

2. Open the electrical compartment at the rear of

3. Discharge the capacitor in the controller by con-

1. POSITIVE CONNECTION (BT+) 1. POSITIVE CONNECTION (BT+)

Covers and Floor Plates

1. CAPSCREW 7. ANTI-SLIP PAD

Figure 5. Covers and Floor Plates

Overhead Guard Repair

2. Route the wires through each overhead guard

3. Lower overhead guard supports onto the mounts.

4. Install and tighten six capscrews, washers, and

5. Remove sling and overhead guard.

Figure 6. Overhead Guard Mounting

Hood and Seat Assembly

1. SEAT 2. HOOD 3. SEAT SWITCH CONNECTOR

Figure 7. Hood and Seat Assembly

5. Disconnect the double-dampened, gas-controlled

6. Remove capscrews securing hood mounting

7. Slide hood mounting brackets from studs on

8. Remove the capscrews, washers, and nuts retain-

2. Install new bushings to mounting brackets if nec-

11. Connect the battery connector.

A one-piece, cast iron counterweight is used to off-

A battery platform is used to support the battery on

NOTE: It may not be necessary to remove the battery

5. Install the controller panel to the inside of the

8. Install a clevis on each of the overhead guard

9. Remove the four M20 × 2.5 × 60 capscrews and

10. Use the overhead lifting device to lift the coun-

b. Install the two capscrews, washers, and nuts

A. SIDE VIEW B. REAR VIEW C. FRONT VIEW

Figure 11. Label Locations - General

100 SRM 1073 6/04 Printed in United Kingdom

PART NO. 1566043 620 SRM 1115

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

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

This section is for the following models:

J1.6-2.0XMT (J30-40ZT) [J160]

©2004 HYSTER COMPANY i

Figure 1. Truck Orientation

3. Open the electrical compartment: