SECTION 9010

OPERATIONAL DIAGNOSTIC PROCEDURES

TABLE OF CONTENTS
Group 05 - Operational Checkout
Operational Checkout Procedures..........................................................................................................9010-
05-1
Key Icon Illuminated........................................................................................................................... 9010-05-2
Wrench Icon Illuminated..................................................................................................................... 9010-05-2
Display Panel (DP) Check.................................................................................................................. 9010-05-2
Operator Presence System Check..................................................................................................... 9010-05-3
Display Backlight and Icon Power Check........................................................................................... 9010-05-4
Light Circuit Check..............................................................................................................................9010-05-5
Horn Circuit Check..............................................................................................................................9010-05-5
Backup Alarm Check (If equipped)..................................................................................................... 9010-05-5
Heater Check (If equipped).................................................................................................................9010-05-5
Brake Pedal Check............................................................................................................................. 9010-05-6
Park Brake Sensor Check.................................................................................................................. 9010-05-6
SAFETY PRECAUTIONS
Park Brake Check

TROUBLESHOOTING PROCEDURES
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Hyster® dealer.
Service Manuals provide general guidelines for maintenance and service and are intended for use by
trained and experienced technicians. Failure to properly maintain equipment or to follow instructions
contained
in the Service Manual could result in damage to the products, personal injury, property damage or
death.
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the
load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the
weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift
trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK
ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed
the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to
remove
parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit
needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable.
Be sure to follow the necessary safety precautions when handling these fuels and when working on these
fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area.
Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this manual:
WARNING
Indicates a condition that can cause immediate death or injury!
CAUTION
Indicates a condition that can cause property damage!
On the lift truck, the WARNING symbol and word are on orange background.
The CAUTION symbol and word are on yellow background.
©2016 HYSTER COMPANY
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
i
How To Use This Troubleshooting Manual
GENERAL INSTRUCTIONS AND SAFETY
INFORMATION
WARNING
DO NOT add to or modify the lift truck. Any modification
that affects the safe operation of the truck
cannot be undertaken without written authorization
of the Hyster company.
Any change to the lift truck, the tires, or its equipment
can change the lifting capacity. The lift truck
must be rated as equipped and the nameplate
must show the new rating capacity.
WARNING
The technician must be aware of, and follow, all
general safety precautions that are published in
the Operating Manual and that are posted as
Safety Decals on and in the lift truck.
Before starting, the technician should be familiar with
certain policies, requirements, and instructions used
in the troubleshooting procedures. Using the troubleshooting
procedures correctly helps the technician to
perform the procedure safely and prevents damage to
the machine and support equipment.
HOW TO USE DIAGNOSTIC
TROUBLESHOOTING MANUAL
Manual Layout:
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 subdivided
into groups, where applicable, that identify
specific functions, operating criteria, or maintenance
tasks.
• 01 – Introduction to the Troubleshooting Manual
• 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 section
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 includes,
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
Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
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 information
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 resolving
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 resolving
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 section
of manual, in this case, the Light
Circuit Check in the Operational Checkout
part of this manual.
The instruction would read, "refer to, or
see" followed by text identifying what the
reference is (for hard-copy, paper manual
use). When the cursor is placed over
the text, it will then indicate that it is active,
and left-clicking will direct the system
to take you directly to that reference.
Try it using the process below:
See Operational Diagnostic Procedures,
Operational Checkout, Page 9010-05-
5.
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
Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
iv Confidential/Proprietary - Do Not Copy or
Duplicateркенцу656456твапрмисми.............................................................................................................
..................9010-05-7
Brake and Axle Drag Check............................................................................................................... 9010-05-8
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................................................................................................................... 9010-05-10
Tilt Racking Check............................................................................................................................9010-05-11
Tilt Function, Tilt Lock Piston............................................................................................................9010-05-11
Mast Cushion Check - Main Lift Cylinder..........................................................................................9010-05-11
Mast Channel Check........................................................................................................................ 9010-05-12
Mast Mounting Check....................................................................................................................... 9010-05-12
Chain and Header Hose Adjustment Check..................................................................................... 9010-05-13
Chain Sheave Check........................................................................................................................ 9010-05-14
Carriage Adjustment Check..............................................................................................................9010-05-14
Carriage Adjustment Check (Standard and Integral Side Shift)....................................................... 9010-05-14
Steering Relief Valve Low Pressure Check...................................................................................... 9010-05-14
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Confidential/Proprietary - Do Not Copy or Duplicate 9010-1
9010-2
Group 05
Operational Checkout
Operational Checkout Procedures
These procedures are designed so technicians can
make a quick check of the operation of the machine
while sitting in operator’s seat.
WARNING
Be sure to read the warnings prior to performing
the checkout procedures.
WARNING
Before operating the lift truck, FASTEN YOUR
SEAT BELT.
There are a number of operations, if not performed
carefully, that can cause the lift truck to
tip. If you have not read the WARNING page in
front of the Operating Manual, do so NOW. As you
study the following information about how to
properly operate a lift truck, remember the Warnings.
WARNING
Mast parts are heavy and can move. Distances between
parts are small. Serious injury or death can
result if part of the body is hit by parts of the mast
or the carriage.
• Never put any part of the body into or under
the mast or carriage unless all parts are
completely lowered or a safety chain is installed.
Also make sure the power is OFF
and the key is removed. Fasten a DO NOT
OPERATE tag in the operator’s compartment.
• Be careful of the forks. When the mast is
raised, the forks can be at a height that may
cause an injury.
• DO NOT climb on the mast or lift truck at
any time. Use a ladder or personnel lift to
work on the mast.
• DO NOT use blocks to support the mast
weldments nor to restrain their movement.
• Mast repairs require disassembly and removal
of parts and can require removal of
the mast or carriage. Follow the repair procedures
in the correct Service Manual for
the mast.
Adequate space is required to do the driving checks.
Some checks require the lift truck and other major
components to be at operating temperature.
Before performing the operational checkout, complete
the INSPECTION BEFORE OPERATION in the Operating
Manual.
Operational Diagnostic Procedures Operational Checkout
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Before starting operational checkout, talk to the operator
and check Diagnostic Trouble Codes (DTC) using
the Display Panel (DP). See Troubleshooting
Guidelines and Procedures. All DTCs must be corrected
or cleared before starting this checkout.
No special tools or gauges are needed. Always start
sequence from left to right. Before doing check, read
each check completely.
At the end of each check, a question is asked:
• If the answer indicates the check is OK, you
will be instructed to go to next check.
• If the answer indicates that the check is not
OK, you will be given a required SRM repair or
be linked to the test to perform.
When a problem is found, stop operational checkout
and correct it before going to the next check. Repeat
check after repair to confirm repair was successful before
proceeding with the remaining checks.
CHECK PROCEDURE ACTION
Key Icon Illuminated
Turn Keyless Start Switch or Key Switch to ON position
with park brake 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 next step.
Wrench Icon Illuminated
Turn Keyless Start Switch or Key Switch to ON position
with park brake applied.
Does the Wrench Icon appear on the Display
and remain illuminated?
YES: Reinstall newest version
of software. See User
Interface Supervisor
2200SRM1335 or User Interface
Service Technician
2200SRM1336.
NO: Display power is OK. Go
to next step.
Display Panel (DP)
Check
1. Turn key or keyless switch to ON position.
2. Check display for any DTCs. See Electrical
System, General Maintenance and Diagnostic
Data, Diagnostic Trouble Codes, Page
9030-03-6.
Are any DTCs displayed?
YES: Refer to Electrical System,
General Maintenance
and Diagnostic Data, Diagnostic
Trouble Codes, Page
9030-03-6.
NO: DTCs are OK. Go to
next check.
Operational Checkout Operational Diagnostic Procedures
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9010-05-2 Confidential/Proprietary - Do Not Copy or Duplicate
Operator Presence
System Check
NOTE: This procedure requires Service Password.
Operator presence sensor requires a minimum of
45.4 kg (100 lb) to actuate.
1. While operator is in seat, power truck ON.
2. See Display Panel Flowchart. At the Display
Panel, Enter Main Display, enter password,
scroll to Diagnostics, Enter.
3. Scroll to Seat Symbol Enter. Read display.
Does display show 1.4 volts or greater?
YES: Continue with this procedure.
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 PROCEEDING TO NEXT CHECK,
RETURN TO SEAT AND FASTEN SEAT BELT.
YES: Operator presence sensor
is OK. Go to next check.
NO: Operator presence sensor
has failed. Replace seat
sensor. See Electrical System
2200SRM1337.
Operational Diagnostic Procedures Operational Checkout
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Display Backlight
and Icon Power
Check
1. INDICATOR LIGHT, PERFORMANCE MODE
2. WARNING LIGHT, LOW BRAKE FLUID
3. WARNING LIGHT, FASTEN SEAT BELT
4. INDICATOR LIGHT, BATTERY DISPLAY INDICATOR
(BDI)
5. INDICATOR LIGHT, DIRECTION INDICATORS
6. INDICATOR LIGHT, LOAD WEIGHT
7. INDICATOR LIGHT, SYSTEM TIME
8. WARNING LIGHT, SERVICE DUE LIGHT
9. WARNING LIGHT, MOTOR TEMPERATURE
HIGH WARNING
10. INDICATOR LIGHT, HAZARD FLASHERS
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 position
with park brake applied.
Do the Display Backlight and icons appear on
the LCD screen?
NOTE: Fasten seat belt, icon will turn off after 10
seconds.
Continue:
YES: Display power is OІвапуківапівап
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