Hyster A276 Manual de programación

Hyster A276 (J45XN, J50XN, J60XN, J70XN) Forklift

DIAGNOSTIC

TROUBLESHOOTING

MANUAL

E2.2-3.5XN (E45-70XN) [A268];

E1.6-2.0XN (E30-40XN) [A269];

J2.2-3.5XN (J45-70XN) [A276];

J1.6-2.0XN (J30-40XN) [A935];

J4.0-5.0XN (J80-100XN) [A970];

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 subsidiaries and/or vendors. Copying or distribution of any sections

of this manual marked "Confidential/Proprietary" is prohibited.

PART NO. 1688885 9000 SRM 1377

SAFETY PRECAUTIONS

TROUBLESHOOTING PROCEDURES

•The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the

product. Updated technical service information may be available from your local authorized Hyster®dealer.

Service Manuals provide general guidelines for maintenance and service and are intended for use by

trained and experienced technicians. Failure to properly maintain equipment or to follow instructions con-

tained in the Service Manual could result in damage to the products, personal injury, property damage or

death.

•When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the

load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the

weight of the load.

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

• Wear safety glasses.

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

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

•Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK

ON BLOCKS in the Operating Manual or the Periodic Maintenance section.

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

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

•Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed

the specifications of the original equipment manufacturer.

•Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to re-

move 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 man-

ual:

WARNING

Indicates a condition that can cause immediate death or injury!

CAUTION

Indicates a condition that can cause property damage!

On the lift truck, the WARNING symbol and word are on orange back-

ground. The CAUTION symbol and word are on yellow background.

TABLE OF CONTENTS

SECTION 9010 - OPERATIONAL DIAGNOSTIC PROCEDURES

Group 05 - Operational Checkout......................................................................................................9010-05-1

SECTION 9025 - TRACTION MOTOR

Group 10 - Principles of Operation....................................................................................................9025-10-1

Group 30 - Observed Symptoms.......................................................................................................9025-30-1

SECTION 9030 - ELECTRICAL SYSTEM

Group 03 - General Maintenance and Diagnostic Data.....................................................................9030-03-1

Diagnostic Trouble Code (DTC) Chart...........................................................................................9030-03-6

Group 10 - Principles of Operation....................................................................................................9030-10-1

Group 20 - Diagnostic Trouble Codes...............................................................................................9030-20-1

Group 30 - Observed Symptoms.......................................................................................................9030-30-1

Group 55 - Icons and Graphics..........................................................................................................9030-55-1

SECTION 9035 - DRIVE AXLE/UNIT

Group 10 - Principles of Operation....................................................................................................9035-10-1

Group 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................................................................................ 9050-43-1

SECTION 9060 - OPERATORS STATION

Group 10 - Principles of Operation....................................................................................................9060-10-1

SECTION 9070 - FRONT END (MAST) AND CHASSIS

Group 10 - Principles of Operation....................................................................................................9070-10-1

Group 30 - Observed Symptoms.......................................................................................................9070-30-1

SECTION 9080 - SUPPLEMENTARY DATA

Group 50 - Abbreviations and Acronyms...........................................................................................9080-50-1

This section is for the following models:

E2.2-3.5XN (E45-70XN) [A268];

E1.6-2.0XN (E30-40XN) [A269];

J2.2-3.5XN (J45-70XN) [A276];

J1.6-2.0XN (J30-40XN) [A935];

J4.0-5.0XN (J80-100XN) [A970];

A1.3XNT, A1.5XNT (A25XNT, A30XNT) [D203];

J1.5-2.0XNT (J30-40XNT) [K160];

E4.0-5.5XN, E5.0XNS (E80-120XV, E100XNS) [A099]

Diagnostic Troubleshooting Manual Table of Contents

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How To Use This Troubleshooting Manual

GENERAL INSTRUCTIONS AND SAFETY

INFORMATION

WARNING

DO NOT add to or modify the lift truck. Any modi-

fication that affects the safe operation of the truck

cannot be undertaken without written authoriza-

tion of the Hyster company.

Any change to the lift truck, the tires, or its equip-

ment can change the lifting capacity. The lift truck

must be rated as equipped and the nameplate

must show the new rating capacity.

WARNING

The technician must be aware of, and follow, all

general safety precautions that are published in

the Operating Manual and that are posted as

Safety Decals on and in the lift truck.

Before starting, the technician should be familiar with

certain policies, requirements, and instructions used

in the troubleshooting procedures. Using the trouble-

shooting procedures correctly helps the technician to

perform the procedure safely and prevents damage to

the machine and support equipment.

HOW TO USE DIAGNOSTIC

TROUBLESHOOTING MANUAL

Manual Layout:

Sections: The manual is divided into eight sections,

each representing a major system, functional area, or

specific operation on the lift truck.

• 9010 – Operational Diagnostic Procedures

• 9025 – Traction Motor

• 9030 – 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-

divided into groups, where applicable, that identify

specific functions, operating criteria, or maintenance

tasks.

• 01 – Introduction to the Troubleshooting Man-

ual

• 03 – General Maintenance/Diagnostic Data

• 05 – Operational Checkout

• 10 – Principles of Operation

• 20 – Diagnostic Trouble Codes

• 30 – Observed Symptoms

• 33 – Observed Symptoms – Gear Pump

• 43 – Test and Adjustments – Gear Pump

• 50 – Abbreviation and Acronyms

• 55 – Icons and Graphics

• 70 – Fault Mode Indicator Reference

For Diagnostic Trouble Code listings, see Electrical

System, General Maintenance and Diagnostic Data,

Diagnostic Trouble Codes, Page 9030-03-6.

NOTE: Not all groups will appear in all sections.

Supplementary Data: The supplementary data sec-

tion of the manual includes information and data that

apply to many sections or groups and is stored here

for access by all users of the manual. This data in-

cludes, but is not limited to:

• Abbreviations and Acronyms

• Special Tools List

• Fault Mode Indication Reference Table

• Supplier Specification Data

How To Use This Troubleshooting Manual Diagnostic Troubleshooting Manual

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ii Confidential/Proprietary - Do Not Copy or Duplicate

GENERAL INSTRUCTIONS

1. Become familiar with the content, layout, and

access provisions of data in this manual. This

will improve your efficiency and decrease the

time required to resolve the problems.

2. Use all sections of the manual for relevant in-

formation on the subject system.

3. Once you begin a troubleshooting procedure,

do not skip steps.

4. If you reach the end of a procedure without re-

solving the problem and you are not directed to

another procedure contact Resident Service

Engineering through the Contact Management

System.

5. Do not limit yourself, remember to apply your

own experience and knowledge to assist in re-

solving the problems, but do not compromise

safety in doing so.

6. Most of the cross-reference data in the manual

will be electronically linked for rapid and easy

access. Use the links wherever the cursor

highlights an item as a linkable option.

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

Circuit Check in the Operational Check-

out part of this manual.

The instruction would read, "refer to, or

see" followed by text identifying what the

reference is (for hard-copy, paper man-

ual use). When the cursor is placed over

the text, it will then indicate that it is ac-

tive, and left-clicking will direct the sys-

tem to take you directly to that refer-

ence.

Try it using the process below:

See Operational Diagnostic Procedures,

Operational Checkout, Page 9010-05-

When you have reviewed the reference

document or manual, and need to return

to the troubleshooting procedure, the

"BACK" button will permit you to do this.

Diagnostic Troubleshooting Manual How To Use This Troubleshooting Manual

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Confidential/Proprietary - Do Not Copy or Duplicate iii

SERVICE MANUAL LOOKUP

The following service manuals are referenced

throughout this manual. Be sure to have the correct

service manual for your lift truck model.

AC Motor Repair 0620SRM1385

• E2.2-3.5XN (E45-70XN) (A268)

• E1.6-2.0XN (E30-40XN) (A269)

• J2.2-3.5XN (J45-70XN) (A276)

• J4.0-5.0XN (A970)

• J1.5-2.0XNT (J30-40XNT) (K160)

• J1.6-2.0XN (J30-40XN) (A935)

• E4.0-5.5XN, 5.0XNS (E80-120XN, E100XNS)

(A099)

AC Motor Repair 0620SRM1515

• A1.3-1.5XNT (A25XNT, A30XNT) (D203)

Brake System 1800SRM1332

• J1.5-2.0XNT (J30-40XNT) (K160)

• J1.6-2.0XN (J30-40XN) (A935)

Brake System 1800SRM1359

• E2.2-3.5XN (E45-70XN) (A268)

Brake System 1800SRM1438

• E1.6-2.0XN (E30-40XN) (A269)

Brake System 1800SRM1518

• A1.3-1.5XNT (A25XNT, A30XNT) (D203)

Capacities and Specifications 8000SRM1340

• J1.5-2.0XNT (J30-40XNT) (K160)

Capacities and Specifications 8000SRM1374

• E2.2-3.5XN (E45-70XN) (A268)

Capacities And Specifications 8000SRM1375

• J2.2-3.5XN (J45-70XN) (A276)

Capacities and Specifications 8000SRM1376

• J1.6-2.0XN (J30-40XN) (A935)

Capacities and Specifications 8000SRM1443

• E1.6-2.0XN (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

• E4.0-5.5XN, 5.0XNS (E80-120XN, E100XNS)

(A099)

Cylinder Repair (Mast S/N A270-72, A551, A555,

A559, A626, A627, A751-52, B551, B555, B586-91,

B749-54, C661-63, C665, D507-09, D515, D562-64,

E509, E564) 2100SRM1382

• E2.2-3.5XN (E45-70XN) (A268)

• J2.2-3.5XN (J45-70XN) (A276)

• J1.5-2.0XNT (J30-40XNT) (K160)

• J1.6-2.0XN (J30-40XN) (A935)

• J4.0-5.0XN (A970)

• E4.0-5.5XN, 5.0XNS (E80-120XN, E100XNS)

(A099)

Cylinder Repair (Mast S/N B551, B555, B559)

2100SRM1440

• E1.6-2.0XN (E30-40XN) (A269)

Cylinder Repair (Mast S/N A270, A271, A272,

C661, C662, C663) 2100SRM1521

• A1.3-1.5XNT (A25XNT, A30XNT) (D203)

Diagrams 8000SRM1341

• J1.5-2.0XNT (J30-40XNT) (K160)

• J1.6-2.0XN (J30-40XN) (A935)

Diagrams 8000SRM1384

• E2.2-3.5XN (E45-70XN) (A268)

• E1.6-2.0XN (E30-40XN) (A269)

• J2.2-3.5XN (J45-70XN) (A276)

• J4.0-5.0XN (A970)

• E4.0-5.5XN, 5.0XNS (E80-120XN, E100XNS)

(A099)

Diagrams 8000SRM1528

• A1.3-1.5XNT (A25XNT, A30XNT) (D203)

Diagnostic Troubleshooting Manual

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iv Confidential/Proprietary - Do Not Copy or Duplicate

Drive Axle Repair 1300SRM1575

• E4.0-5.5XN, 5.0XNS (E80-120XN, E100XNS)

(A099)

Drive Axle, Speed Reducer, and Differential

1300SRM1366

• E2.2-3.5XN (E45-70XN) (A268)

• E1.6-2.0XN (E30-40XN) (A269)

Electrical System 2200SRM1337

• J1.5-2.0XNT (J30-40XNT) (K160)

• J1.6-2.0XN (J30-40XN) (A935)

Electrical System 2200SRM1369

• E2.2-3.5XN (E45-70XN) (A268)

• E1.6-2.0XN (E30-40XN) (A269)

• J2.2-3.5XN (J45-70XN) (A276)

• J4.0-5.0XN (A970)

• E4.0-5.5XN, 5.0XNS (E80-120XN, E100XNS)

(A099)

Electrical System 2200SRM1524

• A1.3-1.5XNT (A25XNT, A30XNT) (D203)

Frame 0100SRM1329

• J1.5-2.0XNT (J30-40XNT) (K160)

• J1.6-2.0XN (J30-40XN) (A935)

Frame 0100SRM1342

• E2.2-3.5XN (E45-70XN) (A268)

• E1.6-2.0XN (E30-40XN) (A269)

• J2.2-3.5XN (J45-70XN) (A276)

• J4.0-5.0XN (A970)

• E4.0-5.5XN, 5.0XNS (E80-120XN, E100XNS)

(A099)

Frame 0100SRM1514

• A1.3-1.5XNT (A25XNT, A30XNT) (D203)

Hydraulic System 1900SRM1333

• J1.5-2.0XNT (J30-40XNT) (K160)

• J1.6-2.0XN (J30-40XN) (A935)

Hydraulic System 1900SRM1367

• E2.2-3.5XN (E45-70XN) (A268)

• E1.6-2.0XN (E30-40XN) (A269)

• 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 LIFT TRUCK MODELS

Load Axle 1300SRM1516

• A1.3-1.5XNT (A25XNT, A30XNT) (D203)

Main Control Valves 2000SRM1334

• E2.2-3.5XN (E45-70XN) (A268)

• J2.2-3.5XN (J45-70XN) (A276)

• J4.0-5.0XN (A970)

• E4.0-5.5XN, 5.0XNS (E80-120XN, E100XNS)

(A099)

• J1.5-2.0XNT (J30-40XNT) (K160)

• J1.6-2.0XN (J30-40XN) (A935)

Main Control Valves 2000SRM1439

• E1.6-2.0XN (E30-40XN) (A269)

Main Control Valves 2000SRM1520

• A1.3-1.5XNT (A25XNT, A30XNT) (D203)

Mast Repair (S/N A551, A555, A559, B551, B555,

D507, D562, D508, D563, D509, D564, D515, E509,

E564) 4000SRM1338

• E2.2-3.5XN (E45-70XN) (A268)

• J2.2-3.5XN (J45-70XN) (A276)

Mast Repair (S/N A270, A271, A272) 4000SRM1386

• J1.5-2.0XNT (J30-40XNT) (K160)

• J1.6-2.0XN (J30-40XN) (A935)

Mast Repair (S/N C661, C662, C663, C665)

4000SRM1405

• J1.5-2.0XNT (J30-40XNT) (K160)

• J1.6-2.0XN (J30-40XN) (A935)

Diagnostic Troubleshooting Manual

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Confidential/Proprietary - Do Not Copy or Duplicate v

Mast Repair (S/N B551, B555, and B559)

4000SRM1441

• E1.6-2.0XN (E30-40XN) (A269)

Mast Repair (S/N A270, A271, A272, C661, C662,

and C663) 4000SRM1525

• A1.3-1.5XNT (A25XNT, A30XNT) (D203)

Mast Repair (S/N A626-27, A751-52, B590-91, and

B749-54) 4000SRM1540

• J4.0-5.0XN (A970)

Mast Repairs (S/N A551, A555, A559, A751, A752,

B586, B587, B588, B590, B591, B749, B750, B751,

B752, and B754) 4000SRM1576

• E4.0-5.5XN, 5.0XNS (E80-120XN, E100XNS)

(A099)

Operator's Cab 0100SRM1446

• E2.2-3.5XN (E45-70XN) (A268)

• J2.2-3.5XN (J45-70XN) (A276)

• J4.0-5.0XN (A970)

• J1.5-2.0XNT (J30-40XNT) (K160)

• J1.6-2.0XN (J30-40XN) (A935)

• A1.3-1.5XNT (A25XNT, A30XNT) (D203)

Periodic Maintenance 8000SRM1339

• J1.5-2.0XNT (J30-40XNT) (K160)

Periodic Maintenance 8000SRM1364

• E2.2-3.5XN (E45-70XN) (A268)

Periodic Maintenance 8000SRM1372

• J2.2-3.5XN (J45-70XN) (A276)

Periodic Maintenance 8000SRM1373

• J1.6-2.0XN (J30-40XN) (A935)

Periodic Maintenance 8000SRM1442

• E1.6-2.0XN (E30-40XN) (A269)

Periodic Maintenance 8000SRM1541

• J4.0-5.0XN (A970)

Periodic Maintenance 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)

• J2.2-3.5XN (J45-70XN) (A276)

• J1.6-2.0XN (J30-40XN) (A935)

• J4.0-5.0XN (A970)

• E4.0-5.5XN, 5.0XNS (E80-120XN, E100XNS)

(A099)

Steering System 1600SRM1331

• J1.5-2.0XNT (J30-40XNT) (K160)

Steering System 1600SRM1363

• E2.2-3.5XN (E45-70XN) (A268)

• E1.6-2.0XN (E30-40XN) (A269)

• J2.2-3.5XN (J45-70XN) (A276)

• J1.6-2.0XN (J30-40XN) (A935)

• J4.0-5.0XN (A970)

• E4.0-5.5XN, 5.0XNS (E80-120XN, E100XNS)

(A099)

Steering System 1600SRM1517

• A1.3-1.5XNT (A25XNT, A30XNT) (D203)

Transaxle 1300SRM1330

• J1.5-2.0XNT (J30-40XNT) (K160)

• J1.6-2.0XN (J30-40XN) (A935)

Transaxle 1300SRM1370

• J2.2-3.5XN (J45-70XN) (A276)

Transaxle 1300SRM1539

• J4.0-5.0XN (A970)

User Interface Service Technician 2200SRM1336

ALL LIFT TRUCK MODELS

User Interface Supervisor 2200SRM1335

ALL LIFT TRUCK MODELS

Wire Harness Repair 2200SRM1128

ALL LIFT TRUCK MODELS

Diagnostic Troubleshooting Manual

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vi Confidential/Proprietary - Do Not Copy or Duplicate

Este manual sirve para los siguientes modelos

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