Hyster A099, Troubleshooting Manual

Page 1: ...Hyster A276 J45XN J50XN J60XN J70XN Forklift...

Page 2: ...A1 3XNT A1 5XNT A25XNT A30XNT D203 J1 5 2 0XNT J30 40XNT K160 E4 0 5 5XN E5 0XNS E80 120XV E100XNS A099 This manual contains information that is confidential and or proprietary to Hyster Company its...

Page 3: ...ON BLOCKS in the Operating Manual or the Periodic Maintenance section Keep the unit clean and the working area clean and orderly Use the correct tools for the job Keep the tools clean and in good con...

Page 4: ...oup 30 Observed Symptoms 9035 30 1 SECTION 9050 HYDRAULIC SYSTEMS Group 10 Principles of Operation 9050 10 1 Group 33 Observed Symptoms Gear Pump 9050 33 1 Group 43 Tests and Adjustments Gear Pump 905...

Page 5: ...ore information Please click here Then get the complete manual NOTE If there is no response to click on the link above please download the PDF document first and then click on it Have any questions pl...

Page 6: ...30 Electrical System 9035 Drive Axle Unit 9050 Hydraulic Systems 9060 Operator s Station 9070 Front End Mast and Chassis 9080 Supplementary Data Groups The sections of the manual are further sub divid...

Page 7: ...hlights an item as a linkable option As an example of this linking option Assume that during a procedure or test it is necessary to refer to a different sec tion of manual in this case the Light Circu...

Page 8: ...2 0XN E30 40XN A269 Capacities and Specifications 8000SRM1527 A1 3 1 5XNT A25XNT A30XNT D203 Capacities and Specifications 8000SRM1542 J4 0 5 0XN A970 Capacities and Specifications 8000SRM1578 E4 0 5...

Page 9: ...J2 2 3 5XN J45 70XN A276 J4 0 5 0XN A970 E4 0 5 5XN 5 0XNS E80 120XN E100XNS A099 Hydraulic System 1900SRM1519 A1 3 1 5XNT A25XNT A30XNT D203 ALL LIFT TRUCK MODELS Industrial Battery 2240SRM0001 ALL...

Page 10: ...nce 8000SRM1526 A1 3 1 5XNT A25XNT A30XNT D203 Periodic Maintenance 8000SRM1577 E4 0 5 5XN 5 0XNS E80 120XN E100XNS A099 Steering Axle 1600SRM1360 E2 2 3 5XN E45 70XN A268 E1 6 2 0XN E30 40XN A269 J2...

Page 11: ...0 01 1 Conventional Battery Box Hyster Unit Code European Model Designation America Model Designation A269 E1 6 2 0XN E30 40XN A268 E2 2 3 5XN E45 70XN A099 E4 0 5 5XN E4 5XNS E80 120XN E100XNS Diagno...

Page 12: ...e European Model Designation America Model Designation D203 A1 3XNT A1 5XNT A25XNT A30XNT K160 J1 5 2 0XNT J30 40XNT A935 J1 6 2 0XN J30 40XN A276 J2 2 3 5XN J45 70XN A970 J4 0 5 0XN J80 100XN Diagnos...

Page 13: ...05 8 Priority Flow Divider Valve Check 9010 05 8 Mast Cushion Check Free Lift Cylinder 9010 05 9 Lift Drift Check 9010 05 9 Lift Tilt Mast Adjustment Check 9010 05 10 Tilt Function Drift Check 9010 0...

Page 14: ...9010 2...

Page 15: ...mpletely lowered or a safety chain is in stalled Also make sure the power is OFF and the key is removed Fasten a DO NOT OPERATE tag in the operator s compart ment Be careful of the forks When the mast...

Page 16: ...ake applied Does the Key Icon appear on the Display and remain illuminated YES Shut key OFF Wait 30 seconds for power cycling then turn key ON Key icon should not stay lit NO Display power is OK Go to...

Page 17: ...NO Go to DTC 12816 Seat Sensor Out of Range Low OORL or DTC 12819 and troubleshoot per procedure Continue While operator is out of seat power truck ON Does display show less than 0 8 volts NOTE BEFORE...

Page 18: ...S 11 INDICATOR LIGHT STEER ANGLE 12 INDICATOR LIGHT FRONT WORK LIGHTS 13 INDICATOR LIGHT REAR WORK LIGHTS Turn Keyless Start Switch or Key Switch to ON posi tion with park brake applied Do the Display...

Page 19: ...uipped 1 With lift truck running apply service brake 2 Release park brake 3 Select reverse direction Does backup alarm sound YES Back up alarm is OK Go to next check NO Check wiring connec tions Heate...

Page 20: ...ee Brake System 1800SRM1332 Park Brake Sensor Check 1 With lift truck running release park brake 2 Slowly apply park brake and note when park brake display comes ON Does display come on before park br...

Page 21: ...ion lift truck with No Load in a downhill di rection on 15 grade or less and apply park brake 5 Shut lift truck OFF and note if machine remains static Does machine remain static on grade in both direc...

Page 22: ...aged If equipped remove differential cover and inspect See Transaxle 1300SRM1330 Priority Flow Di vider Valve Check 1 Turn steering wheel to right axle stop and then back to left axle stop in one cont...

Page 23: ...secured so it will not move when mast is tilted fully for ward Secured capacity load on forks 1 Install angle meter on mast and position mast at approximately 90 angle to ground 2 Raise mast until app...

Page 24: ...shimming is OK Go to next check Tilt Function Drift Check Ensure the following before starting procedure Truck operating on flat surface Hydraulic oil at operating temperature WARNING Ensure load is s...

Page 25: ...before starting procedure Truck operating on flat surface Adequate overhead clearance to raise forks to maximum height WARNING Ensure load is secured so it will not move when mast is tilted fully for...

Page 26: ...If the mast mounting is loose mast will move without moving truck frame Is the mast mounting loose YES Inspect and repair mast mounting See Mast Repair S N A270 A271 A272 4000SRM1386 NO Mast mounting...

Page 27: ...n 0 5 mm 0 020 in at tightest point YES Adjust or repair car riage bearings See Mast Repair S N A270 A271 A272 4000SRM1386 NO Carriage adjustment is OK Go to next check Carriage Adjust ment Check Stan...

Page 28: ...NOTES 9010 05 14...

Page 29: ...or 9025 10 1 Principles of Operation 9025 10 1 MASTER DRIVE UNIT 9025 10 6 Group 30 Observed Symptoms Poor Tractive Performance 9025 30 1 Check the Service Manual section in Hypass Online for possible...

Page 30: ...9025 2...

Page 31: ...erative braking controlled acceleration and deceleration By changing the frequency of the AC power to the motor which is also managed by the motor controller the motor speed can be controlled These AC...

Page 32: ...icle and powers the drive tires The speed sensor for these motors is physically located on the drive unit housing not on the motor See Figure 9025 10 1 1 TRANSMISSION 2 PARKING BRAKE WIRE HARNESS 3 SO...

Page 33: ...HOUSING 6 LEFT SIDE GEARBOX 7 LEFT SIDE TRANSMISSION OUTPUT Figure 9025 10 2 Transaxle Assembly J4 0 5 0XN A970 Traction Motor Principles of Operation Check the Service Manual section in Hypass Online...

Page 34: ...d on the motor itself See Figure 9025 10 3 1 TRANSMISSION 2 TRACTION MOTOR Figure 9025 10 3 Transmission Mounting for Lift Truck Models E2 2 3 5XN E45 70XN A268 and E1 6 2 0XN E30 40XN A269 Principles...

Page 35: ...ion Mounting for Lift Truck Models E4 0 5 5XN E80 120XN A099 Traction Motor Principles of Operation Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams Con...

Page 36: ...ential of damaging the gears when assembling the motor to the MDU By in tegrating the pinion the gear mesh can be better con trolled resulting in a quieter MDU The splined cou pling allows for quick r...

Page 37: ...Service Technician SRM If problem is still present go to Cause C CAUSE C FAILED CHECKLIST ITEM PROCEDURE OR ACTION 1 Review checklist history and run check as required Lift truck will not operate corr...

Page 38: ...e resolved Resume operation CAUSE G MOTOR PHASE SHORTED TO FRAME PROCEDURE OR ACTION 1 Turn lift truck power OFF 2 Disconnect battery 3 Disconnect power cables to tractions motor 4 Change DMM to ohms...

Page 39: ...9030 10 8 System Controlled Outputs 9030 10 11 Power Distribution 9030 10 13 Operator Interface 9030 10 15 E Steer 9030 10 16 Controllers 9030 10 17 Battery Plug In 9030 10 22 Key ON and Operation 903...

Page 40: ...on 12841 Mast Tilt Position 9030 20 62 Travel Direction Select Foot Pedal Manual Hydraulic Out of Range Low OORL 12800 Directional Select A 12804 Directional Select B 9030 20 67 Travel Direction Selec...

Page 41: ...to Traction 1 Right 33027 VSM to Traction 2 Left 33029 VSM to Pump 33034 VSM to MLM DCS 33035 VSM to Impact 33036 VSM to CAN Reserved 1 33037 VSM to CAN Reserved 2 33038 VSM to CAN Reserved 3 33057 Di...

Page 42: ...play Button 3 22535 Display Button 4 22536 Display Button 5 22537 Display Button 6 22538 Display Button 7 22539 Display Button 8 22540 Display Button 9 22541 Display Button 0 9030 20 188 Display Failu...

Page 43: ...citor Charge 9030 20 249 A935 K160 D203 Motor Speed Sensor Failure 29456 Sensor Fault 9030 20 256 CBB DBB Motor Speed Sensor Failure 25104 Sensor Fault 29456 Sensor Fault 9030 20 267 A935 K160 Motor A...

Page 44: ...418 DTC 9012 ACC 2 Current OORH 9030 20 420 DTC 65526 Aux Driver Open 9030 20 420 DTC 65534 Aux Driver Short 9030 20 420 DTC 65288 Loss of Communication Between the Primary and Secondary Controller 9...

Page 45: ...58 5V Internal Supply Out of Range 9030 20 504 DTC 13104 Sensor Ground Current OORH 9030 20 505 DTC 16913 Motor Temperature Sensor Open Circuit 9030 20 509 DTC 16914 Motor Temperature Sensor Short Cir...

Page 46: ...0 Various CAN Errors 9030 20 556 Group 30 Observed Symptoms No Display No Truck Operation None No Display No Truck Operation 9030 30 1 A935 K160 D203 Motor Controller Fan Failure None Motor Controller...

Page 47: ...ions on how to access fault history logs 3 Abbreviations and Acronyms will be defined when first used in a procedure They are also listed and defined in Abbreviations and Acronyms that ac companies th...

Page 48: ...l it clicks dis connects the power supply to the lift truck NOTE The Electrical System Schematic referenced in this manual will be supplied in Diagrams Verify that this data is current and the revisio...

Page 49: ...ift truck is to be stored or shut down verify 1 Mast Carriage Forks are properly posi tioned 2 By pushing the emergency disconnect switch down until it clicks disconnects the power supply to the lift...

Page 50: ...tries The proce dures are graphical in nature with some text explana tion below the relevant graphic In the text explanation symbols are used wherever possible See Icon Glos sary for definitions Minor...

Page 51: ...viewed These may help to isolate the problem eliminate some steps or enforce the procedure that has been identified These items are LOOK Are there any observable symptoms visual evidence or obvious co...

Page 52: ...Data Incorrect No DCS Source 9030 20 353 12808 Accelerator Pedal Position A 9030 20 11 12809 Accelerator Pedal Position A 9030 20 15 12810 Accelerator Pedal Position B 9030 20 11 12811 Accelerator Ped...

Page 53: ...21 12940 Display Keyswitch Output 9030 20 195 12941 Display Keyswitch Output 9030 20 195 13056 5V OORL 9030 20 92 13057 5V OORH 9030 20 92 13058 5V Internal Supply Out of Range 9030 20 504 13060 VSM 1...

Page 54: ...sor 2 Out of Range 9030 20 170 21836 MLM Sensor 3 Out of Range 9030 20 170 21837 MLM Sensor 4 Out of Range 9030 20 170 22032 Display EEPROM Checksum Error 9030 20 188 22033 Display Cell Write Error 90...

Page 55: ...0 20 137 33037 VSM to CAN Reserved 2 9030 20 155 33038 VSM to CAN Reserved 3 9030 20 123 33038 VSM to CAN Reserved 3 9030 20 137 33038 VSM to CAN Reserved 3 9030 20 155 33040 Various CAN Errors 9030 2...

Page 56: ...der Error 9030 20 536 65362 Encoder Error 9030 20 538 65378 Steering Wheel Position Error 9030 20 472 65481 Wrong Slave Version 9030 20 547 65486 Initial VMN High 9030 20 548 65487 Controller Internal...

Page 57: ...188 8786 Brake Coil Shorted 9030 20 279 8960 Lift 9030 20 113 8964 Lower 9030 20 113 8968 Tilt Forward 9030 20 113 8972 Tilt Back 9030 20 113 8976 AC Current Over Current 9030 20 313 8978 Aux 1A 9030...

Page 58: ...rs Wire Function ID numbers will be stamped at 50mm intervals along the wire length The Function IDs are assigned into groups as shown in the table Unless noted otherwise specific functions are to be...

Page 59: ...ed and printed in color If not printed or viewed in color refer to the electrical circuit identification located on schematic circuits When viewing a color version of the diagrams and schematics the w...

Page 60: ...th suffix let ters the base number is not used by itself For exam ple when labeling a circuit 42 start with 42 A rather than 42 Suffix letters should be assigned from A to Z but Q and V are not used A...

Page 61: ...TED TWISTED PAIR SUFFIX LETTER A SHOWN WITH SHIELD THAT TER MINATES AT PIN B2 Figure 9030 03 3 Dual Wiring Sample Circuit Electrical System General Maintenance and Diagnostic Data Check the Service Ma...

Page 62: ...ulics Fig ure 9030 03 13 Wire Harness Display Freezer Fig ure 9030 03 14 Wire Harness Turn Signal Figure 9030 03 15 Wire Harness Synchro Steer Fig ure 9030 03 16 Wire Harness Park Brake Figure 9030 03...

Page 63: ...03 4 J1 5 2 0XNT J30 40XNT K160 Wire Harness Auxiliary Key Switch Electrical System General Maintenance and Diagnostic Data Check the Service Manual section in Hypass Online for possible updates and...

Page 64: ...P VALVE 6 CRP132 MAIN HARNESS 7 CRP133 MAIN HARNESS Figure 9030 03 5 J1 5 2 0XNT J30 40XNT K160 Wire Harness Steering General Maintenance and Diagnostic Data Electrical System Check the Service Manual...

Page 65: ...MARKER LIGHT 6 BUZZER Figure 9030 03 6 J1 5 2 0XNT J30 40XNT K160 Display Wire Harness Standard Electrical System General Maintenance and Diagnostic Data Check the Service Manual section in Hypass On...

Page 66: ...6 CPS165 TEMPERATURE SENSOR 7 BUZZER Figure 9030 03 7 J1 5 2 0XNT J30 40XNT K160 Display Wire Harness Freezer General Maintenance and Diagnostic Data Electrical System Check the Service Manual section...

Page 67: ...Harness Main Electro Hydraulic Electrical System General Maintenance and Diagnostic Data Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams Confidential...

Page 68: ...HORN ASM 28 CPS156 RIGHT CONTROL COOLING FAN 29 TR65 B CONT 30 CPS3 RIGHT TRACTION MOTOR CONTROL LER 31 CPS74 E HYDRAULIC VALVE UPPER COILS 32 CPS75 E HYDRAULIC VALVE LOWER COILS 33 CPS10 LIFT PRESSUR...