Hyster C108 (E2.00-3.00XL) Service Manual

Description

• Model List:
  • C108 (E2.00-3.00XL)

• 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
• 154.4. TORQUE SPECIFICATIONS
• 155.
• 155.1. INTRODUCTION
• 156.
• 156.1. INTRODUCTION
• 156.2. REPAIRS
• 156.3. TROUBLESHOOTING
• 156.4. TORQUE SPECIFICATIONS
• 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. SEAT BRAKE
• 158.4. SPECIFICATIONS
• 158.5. 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. PRINCIPLES OF OPERATION
• 166.
• 166.1. INTRODUCTION
• 166.2. TROUBLESHOOTING
• 166.3. FAULT NEMBER 1. The Direction Contactors Will Not Close For Operation In Either Direction
• 166.4. FAULT NUMBER 2. The Lift Truck Will Not Move In Either Direction. The Direction Contactors Close and The Immediately Open (72-80
• 166.5. FAULT NUMBER 2A. The Lift Truck Will Not Move In Either Direction. The Direction Contactors Close and Then Immediately Open (36-
• 166.6. FAULT NUMBER 3. The Lift Truck Will Not Move In Either Direction. The Direction Contactors Close Normally
• 166.7. FAULT NUMBER 4. The Lift Truck Will Only Move In One Direction. In The Other Direction, The Direction Contactor Closes And Then
• 166.8. FAULT NUMBER 5. One Direction Contactor Will Not Close. The Traction Circuit Operates Normally In Only One Direction.
• 166.9. FAULT NUMBER 6. Contactor 1A Will Not Energize. The Other Operations Of The Lift Truck Are Normal. (36-48 Volt Lift Trucks Equi
• 166.10. FAULT NUMBER 7. Plugging Problems (Lift Trucks Equipped With Only The Plugging Function)
• 166.11. FAULT NUMBER 8. Regenerative Braking Problems (Lift Trucks Equipped With Regenerative Braking)
• 166.12. FAULT NUMBER 9. The Hydraulic Pump Motor Will Not Operate When Any Hydraulic Hand Lever Is Moved From The Neutral Position. (SCR
• 166.13. FAULT NUMBER 10. The Hydraulic Pump Will Not Stop Operating When The Hydraulic Hand Levers Are Returned To The Neutral Position.
• 166.14. FAULT NUMBER 11. The Hydraulic Pump Will Not Operate When One Hydraulic Hand Lever Is Moved For A Hydraulic Function. The Operat
• 166.15. FAULT NUMBER 12. Hydraulic Control Problems (Lift Trucks Equipped With A Hydraulic Pump Contactor)
• 166.16. REPAIRS AND ADJUSTMENTS
• 167.
• 167.1. INTRODUCTION
• 167.2. SRO CIRCUIT AND PMT CIRCUIT (TRACTION CIRCUIT)
• 167.3. TROUBLESHOOTING
• 167.4. LIFT TRUCKS WITHOUT REGENERATIVE BRAKING
• 167.5. LIFT TRUCKS EQUIPPED WITH REGENERATIVE BRAKING
• 168.
• 168.1. INTRODUCTION
• 168.2. DESCRIPTION
• 168.3. CHECKS AND ADJUSTMENTS
• 168.4. REPAIRS
• 168.5. TROUBLESHOOTING
• 169.
• 169.1. ELECTRICAL CHECKS AND ADJUSTMENTS FOR SitDrive) ELECTRICAL LIFT TRUCKS
• 170.
• 170.1. INTRODUCTION
• 170.2. CHECKS AND ADJUSTMENTS
• 170.3. REPAIRS
• 170.4. BATTERY INDICATORS
• 170.5. CONTROLLER FOR THE BATTERY INDICATOR
• 170.6. DISPLAY PANEL COMPONENTS
• 171.
• 171.1. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
• 171.2. LIFT CYLINDERS
• 171.3. REPAIRS
• 171.4. LIFT CYLINDERS FOR VISTA MASTS
• 171.5. CHECKS AND ADJUSTMENTS
• 171.6. TROUBLESHOOTING
• 171.7. SPECIFICATIONS
• 172.
• 172.1. INTRODUCTION
• 172.2. VISTA TWO-STAGE MAST
• 172.3. VISTA FREE-LIFT MAST
• 172.4. VISTA THREE-STAGE MAST
• 172.5. VISTA FOUR-STAGE MAST
• 173.
• 173.1. VISTA MAST, REPAIR
• 173.2. CHECKS AND ADJUSTMENTS
• 173.3. TROUBLESHOOTING
• 174.
• 174.1. INTRODUCTION
• 174.2. REPAIRS
• 174.3. CHECKS AND ADJUSTMENTS
• 174.4. TROUBLESHOOTING
• 175.
• 175.1. INTRODUCTION
• 175.2. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
• 175.3. REPAIRS
• 175.4. CHECKS AND ADJUSTMENTS
• 175.5. TROUBLESHOOTING
• 176.
• 176.1. INTRODUCTION
• 176.2. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
• 176.3. REPAIRS
• 176.4. CHECKS AND ADJUSTMENTS
• 176.5. TROUBLESHOOTING
• 177.
• 177.1. INTRODUCTION
• 177.2. TABLE 1. BOLTS AND SCREWS
• 177.3. TABLE 2. STUDS AND NUTS
• 177.4. TABLE 3. TORQUE NUTS
• 177.5. TABLE 4. TORQUE NUTS WITH NYLON INSERT
• 177.6. TABLE 5. TORQUE VALUES FOR INCH FASTENERS
• 177.7. TABLE 6. TORQUE VALUES FOR METRIC FASTENERS
• 178.
• 178.1. INTRODUCTION
• 178.2. MAINTENANCE SCHEDULE
• 178.3. MAINTENANCE PROCEDURES EVERY 8 HOURS OR DAILY
• 178.4. EVERY 350 HOURS OR TWO MONTHS
• 178.5. EVERY 2000 HOURS OR YEARLY
• 178.6. GENERAL PROCEDURES
• 178.7. WHEELS AND TIRES
• 178.8. SPECIFICATIONS
• 178.9. REFERENCE TABLE
• 179.
• 179.1. BATTERY SPECIFICATIONS
• 179.2. WHEELS AND TIRES
• 179.3. HYDRAULIC SYSTEM
• 179.4. CAPACITIES
• 179.5. UPRIGHT SPEEDS E/J1.25-1.75XL (E25-35XL) (36-48 volt)
• 179.6. UPRIGHT SPEEDS E/J1.25-1.75XL (E25-35XL)(36-48 volt)
• 179.7. UPRIGHT SPEEDS E/J2.00-3.00XL (E/J40-60XL) (36-48 volt)
• 179.8. UPRIGHT SPEEDS E/J2.00-3.00XL (E/J40-60XL) (72-80 volt)
• 179.9. TORQUE SPECIFICATIONS
• 179.10. TORQUE SPECIFICATIONS
• 179.11. EV-100 MOTOR CONTROLLER ADJUSTMENTS (SCR CONTROL FOR HYDRAULIC PUMP)
• 179.12. CABLEFORM MARK XI MOTOR CONTROLLER
• 179.13. UPRIGHT SPEEDS J25-35B (24-36 volt)
• 180.
• 180.1. FIGURE 1. SCHEMATIC DIAGRAM, EV-100 MOTOR CONTROLLER, (AFTER NOVEMBER 1987)
• 180.2. FIGURE 2. SCHEMATIC DIAGRAM, BATTERY INDICATOR WITHOUT LIFT INTERRUPT AND SCR CONTROL FOR HYDRAULIC PUMP MOTOR, (AFTER NOVEMBER
• 180.3. FIGURE 3. SCHEMATIC DIAGRAM, BATTERY INDICATOR WITHOUT LIFT INTERRUPT AND WITH CONTACTOR CONTROL FOR HYDRAULIC PUMP MOTOR, (AFTE
• 180.4. FIGURE 4. SCHEMATIC DIAGRAM, BATTERY INDICATOR WITH LIFT INTERRUPT AND WITH SCR CONTROL FOR HYDRAULIC PUMP MOTOR, (AFTER NOVEMBE
• 180.5. FIGURE 5. SCHEMATIC DIAGRAM, BATTERY INDICATOR WITH LIFT INTERRUPT AND WITH CONTACTOR CONTROL FOR HYDRAULIC PUMP MOTOR, (AFTER N
• 180.6. FIGURE 6. SCHEMATIC DIAGRAM, LED DISPLAY WITH LIFT INTERRUPT AND WITH SCR CONTROL FOR HYDRAULIC PUMP MOTOR, (AFTER NOVEMBER 1987
• 180.7. FIGURE 7. WIRE DIAGRAM, CONTROL SWITCHES (AFTER NOVEMBER 1987)
• 180.8. FIGURE 8. WIRE DIAGRAM, EV-100 MOTOR CONTROLLER WITH CONTACTOR CONTROL FOR HYDRAULIC PUMP MOTOR (AFTER NOVEMBER 1987)
• 180.9. FIGURE 9. WIRE DIAGRAM, EV-100 MOTOR CONTROLLER WITH REGENERATIVE BRAKING, SCR CONTROL FOR HYDRAULIC PUMP MOTOR AND FIELD WEAKEN
• 180.10. FIGURE 10. WIRE DIAGRAMS, BATTERY INDICATORS (AFTER NOVEMBER 1987)
• 180.11. FIGURE 11. WIRE DIAGRAMS, BATTERY INDICATORS (AFTER NOVEMBER 1987)
• 180.12. FIGURE 12. SCHEMATIC DIAGRAM, EV-100 MOTOR CONTROLLER WITH REGENERATIVE BRAKING, (BEFORE NOVEMBER 1987)
• 180.13. FIGURE 13. SCHEMATIC DIAGRAM, EV-100 MOTOR CONTROLLER WITHOUT REGENERATIVE BRAKING, (BEFORE NOVEMBER 1987)
• 180.14. FIGURE 14. WIRE DIAGRAM, EV-100 MOTOR CONTROLLER WITH REGENERATIVE BRAKING, (BEFORE NOVEMBER 1987)
• 180.15. FIGURE 15. WIRE DIAGRAM, EV-100 MOTOR CONTROLLER WITHOUT REGENERATIVE BRAKING, (BEFORE NOVEMBER 1987)
• 180.16. FIGURE 16. WIRE DIAGRAM, CONTROL SWITCHES (BEFORE NOVEMBER 1987)
• 180.17. FIGURE 17. WIRE DIAGRAMS, BATTERY INDICATORS (BEFORE NOVEMBER 1987)
• 180.18. FIGURE 18. HYDRAULIC SCHEMATIC, ALL MODELS
• 181.
• 182.
• 182.1. FIGURE 1. EV-100 LX SERIES TRACTION SCHEMATIC DIAGRAM
• 182.2. FIGURE 2. EV-100 LX SERIES BATTERY INDICATOR W/O LIFT INTERRUPT W/PUMP MOTOR SCR CONTROL SCHEMATIC
• 182.3. FIGURE 3. EV-100 LX SERIES BATTERY INDICATOR W/O LIFT INTERRUPT W/O PUMP MOTOR SCR CONTROL SCHEMATIC
• 182.4. FIGURE 4. EV-100 LX SERIES BATTERY INDICATOR W/LIFT INTERRUPT W/PUMP MOTOR SCR CONTROL SCHEMATIC
• 182.5. FIGURE 5. EV-100 LX SERIES BATTERY INDICATOR W/LIFT INTERRUPT, W/O PUMP MOTOR SCR CONTROL SCHEMATIC
• 182.6. FIGURE 6. EV-100 LX SERIES W/BWI DISPLAY AND W/LIFT INTERRUPT – W/PUMP MOTOR SCR CONTROL SCHEMATIC
• 182.7. FIGURE 7. EV-100 LX SERIES WITH GE OR ITW DISPLAY W/LIFT INTERRUPT – W/O PUMP MOTOR SCR CONTROL SCHEMATIC
• 182.8. FIGURE 8. EV-100 LX SERIES W OR W/O ON-DEMAND STEERING WIRING DIAGRAM
• 182.9. FIGURE 9. EV-100 LX SERIES W/O REGEN OR FIELD WEAKENING AND W/O PUMP MOTOR SCR CONTROL WIRING DIAGRAM