Hyster E4.0-5.5XN User manual

USER INTERFACE
SERVICE TECHNICIAN
E4.0-5.5XN, E5.0XNS
(E80-120XN, E100XNS) [A099];
A1.3-1.5XNT (A25-30XNT) [D203];
J1.5-2.0XNT (J30-40XNT) [K160];
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]
PART NO. 1688879 2200 SRM 1336

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• 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 in-
structions 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 ex-
ceed 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 flamma-
ble. 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 hazardous situation which, if not avoided, could result in death
or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and 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.

©2014 HYSTER COMPANY
TABLE OF CONTENTS
General .....................................................................................................................................................................1
Description .......................................................................................................................................................... 1
Display Panel Menu Access ................................................................................................................................1
Menu Flowchart ...................................................................................................................................................... 2
Technician Menu Flowchart ...............................................................................................................................2
Menu Navigation .....................................................................................................................................................9
Main Menu Structure .....................................................................................................................................9
Screens and Title Screens ............................................................................................................................ 10
Submenus ......................................................................................................................................................10
Returning to the Main Menu ....................................................................................................................... 11
Icons and Settings ........................................................................................................................................ 11
Soft Keys ....................................................................................................................................................... 11
Entering Numbers ........................................................................................................................................12
Icon Glossary ......................................................................................................................................................... 12
Introduction .......................................................................................................................................................12
Soft Key Icons ....................................................................................................................................................13
Overlay Icons .....................................................................................................................................................14
System Off Screen and Alert Screens .............................................................................................................. 14
Main Menu Title Screens ................................................................................................................................. 19
Submenu Icons Grouped by Menu ................................................................................................................... 20
Operating Screen Icons ................................................................................................................................ 20
Password Screen Icons ................................................................................................................................. 22
Activity Log Submenu Icons ........................................................................................................................ 22
Calibration Submenu Icons ..........................................................................................................................24
Display Submenu Icons ................................................................................................................................28
Status Submenu Icons ..................................................................................................................................30
Truck Setup Submenu Icons ........................................................................................................................ 35
Diagnostics Submenu Icons ......................................................................................................................... 49
Operating Screen ...................................................................................................................................................59
Introduction .......................................................................................................................................................59
Performance Mode Controls ............................................................................................................................. 60
Status and Warning Icons ................................................................................................................................ 61
Battery Discharge Indicator .............................................................................................................................62
Direction and Parking Brake Indicators ......................................................................................................... 63
Hazard Flashers and Lighting Controls ..........................................................................................................63
Steer Angle Indicator ........................................................................................................................................63
System Time ......................................................................................................................................................63
Load Weight Indicator ...................................................................................................................................... 63
System Off/Alert Screens ......................................................................................................................................64
Introduction .......................................................................................................................................................64
System Off Screen .............................................................................................................................................64
Alert Screens ..................................................................................................................................................... 65
Password Screen ....................................................................................................................................................66
Introduction .......................................................................................................................................................66
Password Screen ............................................................................................................................................... 66
Service Technician Password Setup ............................................................................................................ 66
Adding/Removing/Changing Passwords .......................................................................................................... 67
Password Log .................................................................................................................................................... 71
Activity Log Menu ................................................................................................................................................. 71
Introduction .......................................................................................................................................................71
User Interface Service Technician Table of Contents
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TABLE OF CONTENTS (Continued)
Operator Checklist Log .....................................................................................................................................72
Password Log .................................................................................................................................................... 75
Impact Events Log ............................................................................................................................................ 77
Calibration Menu .................................................................................................................................................. 79
Introduction .......................................................................................................................................................79
Load Weight Calibration .................................................................................................................................. 80
Return to Set Tilt Stop Point Calibration ........................................................................................................80
E-Hydraulic and Manual Valve Threshold Calibration ..................................................................................80
Steering Wheel Knob Center Point Calibration ..............................................................................................81
Steer Axle Position Calibration ........................................................................................................................82
Manual Hydraulics Calibration ....................................................................................................................... 82
Display Menu .........................................................................................................................................................83
Introduction .......................................................................................................................................................83
Set Date and Time Format Menu .................................................................................................................... 83
Set Daylight Saving Time Menu ......................................................................................................................86
Procedure for Setting Up Automatic Daylight Savings Time .................................................................... 86
Set Time and Date Menu ..................................................................................................................................90
Procedure for Setting Time and Date ..........................................................................................................91
Set Units Menu ................................................................................................................................................. 91
Status Menu .......................................................................................................................................................... 92
Introduction .......................................................................................................................................................92
VSM Versions ....................................................................................................................................................92
Display Versions ............................................................................................................................................... 93
Truck Serial Number ........................................................................................................................................93
Hour Meters ...................................................................................................................................................... 93
E-Hydraulic Controller Versions ......................................................................................................................94
Pump Motor Controller Versions ..................................................................................................................... 94
Traction Motor Controller 1 Versions ..............................................................................................................94
Traction Motor Controller 2 Versions ..............................................................................................................94
Light Controller Versions .................................................................................................................................94
Impact Sensor Versions .................................................................................................................................... 94
Truck Setup Menu .................................................................................................................................................95
Introduction .......................................................................................................................................................95
Add/Remove Password ......................................................................................................................................96
Motor Braking ...................................................................................................................................................96
Changing the Motor Braking Settings ........................................................................................................ 96
Battery Setup .................................................................................................................................................... 97
BDI Adjustment Setting ...................................................................................................................................98
Acceleration Rates ............................................................................................................................................ 99
Hour Meter Initialization ............................................................................................................................... 100
Impact Monitor Shutdown ..............................................................................................................................100
Operator Checklist ..........................................................................................................................................101
Minimum Pump Standby Flow Rate ............................................................................................................. 101
Scheduled Maintenance Reminder ................................................................................................................ 102
Traction Speed Limit ...................................................................................................................................... 103
Return to Set Tilt ............................................................................................................................................ 103
Auto Power-Off Time Delay ............................................................................................................................104
Impact Monitor Settings .................................................................................................................................104
Impact Detection .........................................................................................................................................105
Setting Adjustments ...................................................................................................................................105
Table of Contents User Interface Service Technician
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TABLE OF CONTENTS (Continued)
Initial Adjustment of Soft and Hard Impact Settings .............................................................................. 105
Readjustment of Soft and Hard Impact Settings. .....................................................................................105
Motion Alarm .................................................................................................................................................. 106
Lift Hydraulic Function Maximum Speed and Ramp Times ....................................................................... 106
Lower Hydraulic Function Maximum Speed and Ramp Times ................................................................... 106
Tilt Forward Hydraulic Function Maximum Speed and Ramp Times ........................................................ 107
Tilt Backward Hydraulic Function Maximum Speed and Ramp Times ......................................................107
Auxiliary 1A Hydraulic Function Maximum Speed and Ramp Times ........................................................ 107
Auxiliary 1B Hydraulic Function Maximum Speed and Ramp Times ........................................................ 107
Auxiliary 2A Hydraulic Function Maximum Speed and Ramp Times ........................................................ 107
Auxiliary 2B Hydraulic Function Maximum Speed and Ramp Times ........................................................ 108
Optional Hydraulic Functions ........................................................................................................................108
Rear Lights Control ........................................................................................................................................ 108
Restore Default Settings .................................................................................................................................109
Diagnostics Menu ................................................................................................................................................109
Introduction .....................................................................................................................................................109
Fault Code Log ................................................................................................................................................ 110
Fault Log Details ........................................................................................................................................ 110
Speedometer ....................................................................................................................................................111
Direction Switch ..............................................................................................................................................112
Traction Motor 1 Status ..................................................................................................................................112
Traction Motor 2 Status ..................................................................................................................................113
Occupancy Sensor ........................................................................................................................................... 113
Brake System Sensors .................................................................................................................................... 113
Pump Status ....................................................................................................................................................114
Hydraulic Control Inputs ............................................................................................................................... 114
E-Hydraulic Valves .........................................................................................................................................115
Hydraulic Sensors ...........................................................................................................................................115
System Voltages ..............................................................................................................................................116
Steering Position Sensors ...............................................................................................................................116
This section is for the following models:
E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) [A099];
A1.3-1.5XNT (A25-30XNT) [D203];
J1.5-2.0XNT (J30-40XNT) [K160];
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]
User Interface Service Technician Table of Contents
iii