Hyster C098 (E3.50-5.50XL) Service Manual

Description

• Model List:
  • C098 (E3.50-5.50XL)

• 1. INTRODUCTION
• 2. GENERAL
• 3. LEAD-ACID BATTERIES
• 4. SPECIFIC GRAVITY
• 5. THE CHEMICAL REACTION IN A CELL
• 6. ELECTRICAL TERMS
• 7. HOW TO SELECT THE BATTERY
• 8. VOLTAGE OF A BATTERY
• 9. THE BATTERY AS A COUNTERWEIGHT
• 10. BATTERY RATINGS
• 11. Kilowatt-Hours
• 12. BATTERY MAINTENANCE
• 13. SAFETY PROCEDURES
• 14. MAINTENACE RECORDS
• 15. THE NEW BATTERY
• 16. HOW TO CLEAN THE BATTERY
• 17. HOW TO ADD WATER
• 18. THE HYDROMETER
• 19. BATTERY TEMPERATURE
• 20. CHARGING THE BATTERY
• 21. Types Of Battery Charges
• 22. Methods Of Charging
• 23. Troubleshooting The Charger
• 24. How To Know When The Battery Is Fully Charged
• 25. WHERE TO CHARGE THE BATTERIES
• 26. Equipment Needed
• 27. BATTERY CONNECTORS
• 28. BATTERY CARE
• 29. INTRODUCTION
• 30. GENERAL
• 31. DESCRIPTION
• 32. REPAIRS
• 33. OVERHEAD GUARD
• 34. Removal
• 35. Installation
• 36. BATTERY RESTRAINT AND SEAT ASSEMBLY
• 37. COUNTERWEIGHT
• 38. Removal
• 39. Installation
• 40. TRACTION MOTOR
• 41. Removal
• 42. Installation
• 43. HYDRAULIC TANK
• 44. Inspection
• 45. Repairs, Smalls Leaks
• 46. Repairs, Large Leaks
• 47. Cleaning
• 48. Steam Method Of Cleaning
• 49. Chemical Solution Method Of Cleaning
• 50. Additional Preparations For Repair
• 51. PAINTING INSTRUCTIONS
• 52. LABEL REPLACEMENT
• 53. INTRODUCTION
• 54. GENERAL
• 55. DESCRIPTION
• 56. OPERATION
• 57. Lift Section
• 58. Tilt Section
• 59. Relief Valve
• 60. SOLENOID VALVE FOR AUXILIARY FUNCTION
• 61. Operation
• 62. REPAIRS
• 63. MAIN CONTROL VALVE
• 64. Removal and Disassembly
• 65. Cleaning and Inspection
• 66. Assembly
• 67. Installation
• 68. SOLENOID VALVE FOR AUXILIARY FUNCTION
• 69. Removal and Disassembly
• 70. Assembly and Installation
• 71. CHECKS AND ADJUSTMENTS
• 72. PRESSURE RELIEF VALVES
• 73. Primary Relief Valve
• 74. Seconday Relief Valve
• 75. CONTROL LEVER ARRANGEMENT
• 76. TROUBLESHOOTING
• 77. SPECIFICATIONS
• 78. INTRODUCTION
• 79. MAGNETISM
• 80. MAGNETISM AND PERMANENT MAGNETS
• 81. ELECTROMAGNETIC FIELDS
• 82. ELECTROMAGNETS
• 83. ELECTROMAGNETIC INDUCTION
• 84. MAGNETIC FORCE ON A CONDUCTOR
• 85. BASIC MOTORS
• 86. MOTOR OPERATION
• 87. COMMUTATION PRINCIPLE
• 88. DIRECTION OF MOTOR ROTATION
• 89. MOTOR SPEED
• 90. MOTOR TORQUE
• 91. COUNTER ELECTROMOTIVE FORCE
• 92. TYPICAL MOTOR
• 93. TYPES OF MOTORS
• 94. PermanentMagnet
• 95. Series Wound
• 96. Parallel or Shunt Wound
• 97. Compound Wound
• 98. MOTOR INSULATION CLASS
• 99. STORAGE
• 100. HANDLING
• 101. BREAKIN OPERATION
• 102. CLEANING
• 103. BASIC REPAIR GUIDELINES
• 104. BEARINGS, SEALS AND LUBRICATION
• 105. BRUSHES AND BRUSH HOLDERS
• 106. ARMATURE
• 107. COMMUTATOR
• 108. Description
• 109. SATISFACTORY SURFACE
• 110. STREAKING AND THREADING SURFACE
• 111. GROOVING ON SURFACE
• 112. COPPER DRAG ON SURFACE
• 113. OVERHEATING
• 114. FIELD ASSEMBLY
• 115. INSPECTION CHECKLIST
• 116. CHECKING AND REPLACING MOTOR BRUSHES
• 117. Inspecting Brushes
• 118. INSPECT THE COMMUTATOR
• 119. REPLACING BRUSHES
• 120. SEATING BRUSHES (STONING PROCEDURE)
• 121. CHECK THE MOTORS FOR OPENS, GROUNDS AND SHORTS
• 122. Check The Motor For Opens
• 123. Check The Motor For Grounds
• 124. Check The Motor For Shorts
• 125. COMMUTATOR INSPECTION
• 126. POLISHING COMMUTATOR
• 127. TURNING COMMUTATOR
• 128. UNDERCUTTING COMMUTATOR
• 129. SLOT RAKING AND BRUSHING COMMUTATOR
• 130. INTRODUCTION
• 131. ELECTRIC MOTOR MAINTENANCE, GENERAL
• 132. BRUSH AND COMMUTATOR INSPECTION
• 133. Hydraulic Pump Motor And Traction Motor
• 134. Steering Pump Motor
• 135. TROUBLESHOOTING
• 136. TROUBLESHOOTING
• 137. Commutator Problems
• 138. BRUSH REPLACEMENT
• 139. DISASSEMBLY OF MOTORS
• 140. Traction Motor And Hydraulic Pump Motor
• 141. Steering Pump Motor
• 142. ASSEMBLY OF MOTORS
• 143. Traction Motor And Hydraulic Pump Motor
• 144. Steering Pump Motor
• 145. BRUSH ALIGNMENT, TRACTION AND HYDRAULIC MOTORS
• 146. TESTS FOR A DAMAGED FIELD AND ARMATURE
• 147. Test For An Open Circuit In The Armature
• 148. Test For A ShortCircuit In One Armature Winding
• 149. Test For A ShortCircuit To Armature Shaft
• 150. Test For An Open Circuit In A Field Coil
• 151. Test For A ShortCircuit In A Field Coil
• 152. Test For A ShortCircuit Between The Field And The Motor Case
• 153. Brush Holder Test
• 154.
• 154.1. INTRODUCTION
• 154.2. REPAIRS
• 154.3. TROUBLESHOOTING
• 155.
• 155.1. INTRODUCTION
• 156.
• 156.1. INTRODUCTION
• 156.2. REPAIRS
• 156.3. TROUBLESHOOTING
• 157.
• 157.1. STEERING SYSTEMS FOR ELECTRICAL LIFT TRUCKS
• 157.2. POWER STEERING MOTOR AND PUMP
• 157.3. HYDRAULIC STEERING MOTOR
• 157.4. CHECKS AND ADJUSTMENTS
• 157.5. TROUBLESHOOTING
• 158.
• 158.1. INTRODUCTION
• 158.2. REPAIRS
• 158.3. CHECKS AND ADJUSTMENTS
• 158.4. TROUBLESHOOTING
• 159.
• 159.1. INTRODUCTION
• 159.2. REPAIRS
• 159.3. CHECKS AND ADJUSTMENTS
• 159.4. TROUBLESHOOTING
• 159.5. SPECIFICATIONS
• 160.
• 160.1. INTRODUCTION
• 160.2. REPAIRS
• 160.3. CHECKS AND ADJUSTMENTS
• 160.4. TROUBLESHOOTING
• 161.
• 161.1. INTRODUCTION
• 161.2. DESCRIPTION
• 161.3. CHECKS AND ADJUSTMENTS
• 161.4. REPLACEMENT
• 161.5. SPECIFICATIONS
• 161.6. TROUBLESHOOTING
• 162.
• 162.1. ELECTRICAL WARNING DEVICES
• 163.
• 163.1. EV-100E MOTOR CONTROLLER, DESCRIPTION AND OPERATION
• 163.2. SEQUENCE OF OPERATION
• 164.
• 164.1. EV-100 MOTOR CONTROLLER REPAIRS AND ADJUSTMENTS
• 165.
• 165.1. INTRODUCTION
• 165.2. SRO CIRCUIT AND PMT CIRCUIT (TRACTION CIRCUIT)
• 165.3. TROUBLESHOOTING
• 165.4. LIFT TRUCKS WITHOUT REGENERATIVE BRAKING
• 165.5. LIFT TRUCKS EQUIPPED WITH REGENERATIVE BRAKING
• 166.
• 166.1. INTRODUCTION
• 166.2. SEQUENCE OF OPERATION
• 166.3. CHECKS AND REPAIRS
• 166.4. ADJUSTMENTS
• 167.
• 167.1. INTRODUCTION
• 167.2. DESCRIPTION
• 167.3. CHECKS AND ADJUSTMENTS
• 167.4. REPAIRS
• 167.5. TROUBLESHOOTING
• 168.
• 168.1. ELECTRICAL CHECKS AND ADJUSTMENTS FOR SitDrive) ELECTRICAL LIFT TRUCKS
• 169.
• 169.1. INTRODUCTION
• 169.2. DESCRIPTION
• 169.3. REPLACEMENT
• 169.4. CHECKS AND ADJUSTMENTS
• 170.
• 170.1. TROUBLESHOOTING AND ADJUSTMENTS WITH A COMPUTER For EV-100ZX, EV-T100, SR (SEM) And SP Motor Controllers
• 171.
• 171.1. Transistor Motor Controllers (SR and SP)
• 171.2. Safety Precautions Maintenance and Repair
• 171.3. Description
• 171.4. Model Number Data for Transistor Motor Controllers (SR and SP)
• 171.5. Motor Controller Checks and Adjustments
• 171.6. Checks and Adjustments Using a Handset
• 171.7. General
• 171.8. Connect Handset
• 171.9. Start Sequence
• 171.10. Check or Delete Stored Status Codes
• 171.11. Returning Lift Truck to Normal Operation
• 171.12. Checks and Adjustments on Workbench
• 171.13. How to Check and Adjust Registers
• 171.14. Function Parameters Adjustments
• 171.15. General
• 171.16. Function Numbers
• 171.17. When Handset is Connected to Motor Controller in Lift Truck
• 171.18. Function Numbers 1 through 15
• 171.19. Function Numbers 16 through 30
• 171.20. Function Numbers 48 through 63
• 171.21. Function Number Descriptions
• 171.22. Traction Motor Controller (Label Letter – SR)
• 171.23. Functions with Premium Display Panel Only
• 171.24. Pump Motor Controller (Label Letter – SP)
• 171.25. Functions With Premium Display Panel Only
• 171.26. Troubleshooting
• 171.27. General
• 171.28. Status Codes
• 171.29. Status Code Charts
• 171.30. Transistor Motor Controllers Repairs
• 171.31. General
• 171.32. General Maintenance Instructions
• 171.33. Special Precautions
• 171.34. Contactors
• 171.35. Contactor Driver Module
• 171.36. Contactor Driver, Replace
• 171.37. Motor Controller Plug
• 171.38. Brush Wear Indicators
• 171.39. Thermal Sensors
• 171.40. Motor Controller, Replace
• 171.41. Parameter Tables
• 171.42. General
• 171.43. Function Numbers
• 171.44. Motor Controller Checks and Adjustments
• 171.45. Parameter Tables
• 171.46. Theory of Operation
• 171.47. General
• 171.48. SEM System Description
• 171.49. SEM System Operation (SR Motor Controller)
• 171.50. Reverse Circuit
• 171.51. Performance and Efficiency
• 171.52. Field Weakening
• 171.53. Regenerative Braking
• 171.54. Creep Speed
• 171.55. Controlled Acceleration
• 171.56. Current Limit
• 171.57. Braking
• 171.58. Regenerative Braking to Zero Speed
• 171.59. Pedal Position Braking
• 171.60. Auto Braking
• 171.61. Auxiliary Speed Control
• 171.62. Field Weakening
• 171.63. Speed Limits
• 171.64. Ramp Operation
• 171.65. Ramp Start
• 171.66. Anti-Rollback
• 171.67. Steer Pump Contactor Time Delay
• 171.68. Coil Drivers and Internal Coil Suppression
• 171.69. System Protective Override
• 171.70. SRO (Static Return to Off)
• 171.71. Accelerator Volts Hold Off
• 171.72. Pulse Monitor Trip (PMT)
• 171.73. Thermal Protector (TP)
• 171.74. Low Voltage
• 171.75. SP Pump Motor Controllers
• 171.76. Contactor Driver Module
• 171.77. Diagnostics
• 171.78. Systems Diagnostics
• 171.79. Standard Status Codes
• 171.80. Stored Status Codes
• 171.81. Hourmeter Readings
• 171.82. Maintenance Management Capability
• 171.83. Table 1. Speed/Torque Compensation
• 171.84. Table 2. Function Map for Motor Controllers SR (Traction)
• 171.85. Table 3. Function Map for Motor Controllers SP (Lift Pump Motor)
• 171.86. Table 4. List of Status Codes
• 171.87. Table 5. Large (P) Plug (23-Pin) Connections/Descriptions for Mo
• 171.88. Table 6. Small Plug (12-Pin) Connections/Descriptions for Motor
• 171.89. Table 7. Traction Control – SR Transistor Control Settings, 11-I
• 171.90. Table 8. Traction Control – SR Transistor Control Settings, 13-I
• 171.91. Table 9. Traction Control – SR Transistor Control Settings, 13-n
• 171.92. Table 10. Hydraulic Pump – SR Transistor Control Settings (36/48
• 172.
• 172.1. INTRODUCTION
• 172.2. CHECKS AND ADJUSTMENTS
• 172.3. REPAIRS
• 172.4. BATTERY INDICATORS
• 172.5. CONTROLLER FOR THE BATTERY INDICATOR
• 172.6. DISPLAY PANEL COMPONENTS
• 173.
• 173.1. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
• 173.2. LIFT CYLINDERS
• 173.3. REPAIRS
• 173.4. LIFT CYLINDERS FOR VISTA MASTS
• 173.5. CHECKS AND ADJUSTMENTS
• 173.6. TROUBLESHOOTING
• 173.7. SPECIFICATIONS
• 174.
• 174.1. VISTA MASTS
• 174.2. REPAIRS
• 174.3. CHECKS AND ADJUSTMENTS
• 174.4. TROUBLESHOOTING
• 175. _2
• 175.1. VISTA MASTS
• 175.2. REPAIRS
• 175.3. CHECKS AND ADJUSTMENTS
• 175.4. TROUBLESHOOTING
• 176.
• 176.1. INTRODUCTION
• 176.2. TABLE 1. BOLTS AND SCREWS
• 176.3. TABLE 2. STUDS AND NUTS
• 176.4. TABLE 3. TORQUE NUTS
• 176.5. TABLE 4. TORQUE NUTS WITH NYLON INSERT
• 176.6. TABLE 5. TORQUE VALUES FOR INCH FASTENERS
• 176.7. TABLE 6. TORQUE VALUES FOR METRIC FASTENERS
• 177.
• 177.1. INTRODUCTION
• 177.2. MAINTENANCE SCHEDULE
• 177.3. MAINTENANCE PROCEDURES EVERY 8 HOURS OR DAILY
• 177.4. EVERY 350 HOURS OR TWO MONTHS
• 177.5. EVERY 2000 HOURS OR YEARLY
• 177.6. GENERAL PROCEDURES
• 177.7. WHEELS AND TIRES
• 177.8. SPECIFICATIONS
• 177.9. REFERENCE TABLE
• 178.
• 178.1. FIGURE 1. SCHEMATIC DIAGRAM, EV100 OR EV200 SCR TRACTION MOTOR CONTROL, 3648 VOLTS
• 178.2. FIGURE 2. WIRING DIAGRAM, EV100 SCR TRACTION MOTOR CONTROL WITH SINGLE OR DUAL HYDRAULIC PUMP MOTOR CONTACTOR CONTROL
• 178.3. FIGURE 3. WIRING DIAGRAM, EV200 SCR TRACTION MOTOR CONTROL WITH EV100 SCR HYDRAULIC PUMP MOTOR CONTROL
• 178.4. FIGURE 4. WIRING DIAGRAM, CONTROL SWITCHES
• 178.5. FIGURE 5. HYDRAULIC PUMP MOTOR CONTROLS (1 OF 3)
• 178.6. FIGURE 6. BATTERY INDICATORS
• 178.7. FIGURE 7. HYDRAULIC SCHEMATIC
• 178.8. FIGURE 8. SCHEMATIC AND WIRING DIAGRAM 12V LIGHTS
• 179.
• 179.1. FIGURE 1. SCHEMATIC DIAGRAM, EV-100 OR EV-200 SCR TRACTION MOTOR CONTROL, 36-48 VOLTS
• 179.2. FIGURE 2. WIRING DIAGRAM, EV-100 SCR TRACTION MOTOR CONTROL WITH SINGLE OR DUAL HYDRAULIC PUMP MOTOR CONTACTOR CONTROL
• 179.3. FIGURE 3. WIRING DIAGRAM, EV-200 SCR TRACTION MOTOR CONTROL WITH EV-100 SCR HYDRAULIC PUMP MOTOR CONTROL
• 179.4. FIGURE 4. WIRING DIAGRAM, CONTROL SWITCHES (1 OF 2)
• 179.5. FIGURE 5. HYDRAULIC PUMP MOTOR CONTROLS (1 OF 4)
• 179.6. FIGURE 6. EV-100 LX SERIES GE OR ITW DISPLAY WITH LIFT INTERRUPT – WITHOUT PUMP MOTOR SCR CONTROL SCHEMATIC
• 179.7. FIGURE 7. BATTERY INDICATORS