Hyster C203 (A1.00-1.50XL) Service Manual

Description

• Model List:
  • C203 (A1.00-1.50XL)

• 1. RM0374-(03-1993)-UK-EN
• 1.1. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
• 1.2. INTRODUCTION
• 1.3. LIFT CYLINDERS
• 1.4. CHECKS AND ADJUSTMENTS
• 2. RM0485-(07-2000)-UK-EN
• 2.1. STEERING SYSTEMS FOR ELECTRICAL LIFT TRUCKS
• 2.2. POWER STEERING MOTOR AND PUMP
• 2.3. HYDRAULIC STEERING MOTOR
• 2.4. CHECKS AND ADJUSTMENTS
• 2.5. TROUBLESHOOTING
• 3. RM0222-(04-2000)-UK-EN
• 3.1. INTRODUCTION
• 3.2. VISTA TWO-STAGE MAST
• 3.3. VISTA FREE-LIFT MAST
• 3.4. VISTA THREE-STAGE MAST
• 3.5. VISTA FOUR-STAGE MAST
• 4. RM0001-(01-2016)-UK-EN
• 4.1. General
• 4.2. Lead-Acid Batteries
• 4.3. Specific Gravity
• 4.4. Chemical Reaction in a Cell
• 4.5. Electrical Terms
• 4.6. Battery Selection
• 4.7. Battery Voltage
• 4.8. Battery as a Counterweight
• 4.9. Battery Ratings
• 4.10. Battery Maintenance
• 4.11. Troubleshooting
• 5. RM0145-(02-1997)-UK-EN
• 5.1. INTRODUCTION
• 5.2. MAGNETISM
• 5.3. BASIC MOTORS
• 6. RM0103-(03-2007)-UK-EN
• 6.1. Tilt Cylinders
• 6.2. Safety Precautions Maintenance and Repair
• 6.3. General
• 6.4. Description
• 6.5. Tilt Cylinder Repair
• 6.6. Disassemble
• 6.7. Assemble
• 6.8. Tilt Cylinders With O-Ring or Single-Lip Seals
• 6.9. Tilt Cylinders for XM and XMS Models
• 6.10. Tilt Cylinders for XL, XLS, and XL 3 Models
• 6.11. Tilt Cylinders for H700-800A and Early Model H700-920B
• 6.12. Install
• 6.13. Tilt Cylinders Using Chevron Packing
• 6.14. Tilt Cylinder Leak Check
• 6.15. Tilt Cylinder Stroke and Mast Tilt Angle Adjustment
• 6.16. Torque Specifications
• 6.17. Piston Rod Nut
• 6.18. Retainer
• 6.19. Troubleshooting
• 6.20. Table 1. Movement Rates (Maximum) for Tilt Cylinders
• 7. RM0143-(02-2007)-UK-EN
• 7.1. Instrument Panel Indicators and Senders
• 7.2. Safety Precautions Maintenance and Repair
• 7.3. General
• 7.4. Description
• 7.5. Steering Column Gauges, Meters, and Indicators
• 7.6. LED Display Panel
• 7.7. Battery Discharge Indicators
• 7.8. Brush Wear Indicators
• 7.9. Motor Temperature Indicators
• 7.10. LX Series Display Panel
• 7.11. Hourmeter Functions
• 7.12. Battery Indicator Function
• 7.13. Status Code Function
• 7.14. ZX Series Display Panels
• 7.15. Display Panel
• 7.16. Basic Display Panels
• 7.17. Performance Display
• 7.18. Brush Wear Indicators
• 7.19. Adjustments – General
• 7.20. Replacement – General Information
• 7.21. Meter Replacement
• 7.22. Sender Replacement
• 7.23. Fuel Level Sender
• 7.24. Pressure and Temperature Sender
• 7.25. Seat Sensor, Operator Presence System (OPS)
• 7.26. Install
• 7.27. Operator Presence System Module Replacement
• 7.28. Install
• 7.29. ITW Display Panel Replacement
• 7.30. Column Mount Display Panel (EV-100/200ZX Motor Controllers) Repl
• 7.31. Display Panel Assembly, Replace
• 7.32. Indicator LEDs
• 7.33. Battery Indicators
• 7.34. Digital Display (Performance Display Panel Only)
• 7.35. Status Code or Performance Level Switches and Indicator LEDs (Pe
• 7.36. Basic Display Panel, Replace Parts
• 7.37. Performance Display Panel, Replace Parts
• 7.38. Dash Mount Display Panel (EV100/200ZX Motor Controllers) Replace
• 7.39. Remove and Replace
• 7.40. Specifications
• 7.41. Meter Specifications
• 7.42. Sender Specifications
• 7.43. Troubleshooting
• 7.44. Troubleshooting for Operator Presence System
• 7.45. Table 1. Troubleshooting Procedure for Operator Presence Module
• 8. RM0144-(05-1997)-UK-EN
• 8.1. ELECTRICAL WARNING DEVICES
• 9. RM0138-(06-2002)-UK-EN
• 9.1. INTRODUCTION
• 9.2. CHECKS AND ADJUSTMENTS
• 9.3. REPAIRS
• 9.4. BATTERY INDICATORS
• 9.5. CONTROLLER FOR THE BATTERY INDICATOR
• 9.6. DISPLAY PANEL COMPONENTS
• 10. RM0231-(01-2016)-UK-EN
• 10.1. General
• 11. RM0793-(03-2000)-UK-EN
• 11.1. Safety Precautions Maintenance and Repair
• 11.2. General
• 11.3. Description
• 11.4. Overhead Guard Repair
• 11.5. Install
• 11.6. Hood and Seat Assembly Repair
• 11.7. Install
• 11.8. Counterweight Repair
• 11.9. Install
• 11.10. Hydraulic Tank Repair
• 11.11. Inspect
• 11.12. Small Leaks, Repair
• 11.13. Large Leaks, Repair
• 11.14. Steam Method
• 11.15. Chemical Solution Method
• 11.16. Additional Preparations for Repair
• 11.17. Safety Labels
• 11.18. Battery Specifications
• 11.19. Table 1. Weight of Counterweights
• 12. RM0794-(05-2000)-UK-EN
• 12.1. Master Drive Unit (ZF)
• 12.2. Safety Precautions Maintenance and Repair
• 12.3. General
• 12.4. Description
• 12.5. Top Section Housing
• 12.6. Transmission Housing
• 12.7. Disassemble
• 12.8. Top Section Housing
• 12.9. Transmission Housing
• 12.10. Assemble
• 12.11. Installing Spiral Bevel Pinion Shaft
• 12.12. Measuring Bearing Movement in Bevel Pinion Shaft
• 12.13. Assembly of Helical Gear
• 12.14. Assembling Crown Gear and Wheel Shaft
• 12.15. Assembling Transmission Housing Cover
• 12.16. Assembling Input Motor Pinion Gear
• 12.17. Inspecting Top Section Housing
• 12.18. Measuring Pivoting Bearing Movement
• 12.19. Installing Top Section Housing
• 12.20. Install
• 12.21. Tooth Contact Pattern Adjustment
• 12.22. Changing Transmission Oil
• 12.23. Troubleshooting
• 12.24. Table 1. Tooth Contact Pattern
• 13. RM0795-(04-2000)-UK-EN
• 13.1. Master Drive Unit (Kordel)
• 13.2. Safety Precautions Maintenance and Repair
• 13.3. General
• 13.4. Description
• 13.5. Upper Section
• 13.6. Lower Section
• 13.7. Drive Unit Repair
• 13.8. Disassemble
• 13.9. Assemble
• 13.10. General
• 13.11. Assemble Component Subassemblies
• 13.12. Assemble Components Into Lower Section
• 13.13. Assemble Upper and Lower Sections
• 13.14. Install
• 13.15. Check and Change Transmission Oil
• 13.16. Tooth Contact Pattern Adjustment
• 13.17. Troubleshooting
• 13.18. Table 1. Tooth Contact Pattern
• 14. RM0797-(03-2000)-UK-EN
• 14.1. Steering Control Unit
• 14.2. Safety Precautions Maintenance and Repair
• 14.3. General
• 14.4. Description
• 14.5. Operation
• 14.6. Steering Wheel and Column Assembly Repair
• 14.7. Steering Column Assembly Repair
• 14.8. Remove and Disassemble
• 14.9. Assemble and Install
• 14.10. Steering Control Unit, Disassemble
• 14.11. Steering Control Unit, Clean
• 14.12. Steering Control Unit, Assemble
• 14.13. System Air Removal
• 14.14. Troubleshooting
• 15. RM0796-(03-2000)-UK-EN
• 15.1. Steering System
• 15.2. Safety Precautions Maintenance and Repair
• 15.3. General
• 15.4. Description
• 15.5. Steering Wheel and Column Assembly
• 15.6. Steering Control Unit Repair
• 15.7. Install
• 15.8. Hydraulic Steering Motor Repair
• 15.9. Description
• 15.10. Disassemble
• 15.11. Clean and Inspect
• 15.12. Assemble
• 15.13. Install
• 15.14. Direction Control Lever Repair
• 15.15. Assemble
• 15.16. Install
• 15.17. Power Steering Adjustments
• 15.18. Air in Steering System
• 15.19. Steering Pressure
• 15.20. Steering Chain, Adjust
• 15.21. Troubleshooting
• 16. RM0803-(03-2000)-UK-EN
• 16.1. Brake System
• 16.2. Safety Precautions Maintenance and Repair
• 16.3. General
• 16.4. Description and Operation
• 16.5. Master Cylinder Repair
• 16.6. Remove and Disassemble
• 16.7. Clean and Inspect
• 16.8. Assemble and Install
• 16.9. Service and Parking Brakes Repair
• 16.10. Remove and Disassemble
• 16.11. Inspect
• 16.12. Assemble and Install
• 16.13. Brake System Air Removal
• 16.14. Service Brakes Adjustment
• 16.15. Brake Pedal Adjustment
• 16.16. Parking Brake Adjustment
• 16.17. Troubleshooting
• 17. RM0802-(02-2009)-UK-EN
• 17.1. Hydraulic System
• 17.2. Safety Precautions Maintenance and Repair
• 17.3. General
• 17.4. Description
• 17.5. Control Valve Repair
• 17.6. Description
• 17.7. Operation
• 17.8. Tilt and Auxiliary
• 17.9. Relief Valve
• 17.10. Check Valves
• 17.11. Repairs
• 17.12. Disassemble – Control Valve Without OPS Solenoids
• 17.13. Disassemble – Control Valve With OPS Solenoids
• 17.14. Relief Valve Repair – Control Valve Without OPS Solenoids
• 17.15. Relief Valve Repair – Control Valve With OPS Solenoids
• 17.16. Clean and Inspect
• 17.17. Assemble – Control Valve Without OPS Solenoids
• 17.18. Assemble – Control Valve With OPS Solenoids
• 17.19. Install
• 17.20. Relief Valve Check
• 17.21. Relief Valve
• 17.22. Control Levers, Linkage, and Switches
• 17.23. Hydraulic Pump Repair
• 17.24. Description
• 17.25. Repairs
• 17.26. Seal, Replace
• 17.27. Install
• 17.28. Specifications
• 17.29. Relief Valves Pressures
• 17.30. Hydraulic System Capacity
• 17.31. Troubleshooting
• 17.32. Hydraulic Pump
• 17.33. Control Valve
• 18. RM0806-(10-2001)-UK-EN
• 18.1. Sevcon SC2126 Motor Controller
• 18.2. Safety Precautions Maintenance and Repair
• 18.3. General
• 18.4. Lift Truck Control
• 18.5. Plugging
• 18.6. Contactors
• 18.7. Circuit Protection
• 18.8. Current Limit
• 18.9. Controller Operation
• 18.10. General Operation
• 18.11. Operating Frequency
• 18.12. Temperature Monitoring
• 18.13. Safe Operating Area (SOA)
• 18.14. Undervoltage and Overvoltage Protection
• 18.15. Diagnostic LED
• 18.16. Fault Clearance
• 18.17. Software Version and Revision Indication
• 18.18. Setup Menu
• 18.19. Multi Languages
• 18.20. Power Circuit Descriptions
• 18.21. Traction Operation
• 18.22. Start Up Sequence
• 18.23. Static Return to Off (SRO)
• 18.24. Seat Switch
• 18.25. Acceleration Delay
• 18.26. Deceleration Delay
• 18.27. Regenerative Braking
• 18.28. Plug Braking
• 18.29. Brake Constant Factor
• 18.30. Antirollback
• 18.31. Analog Inputs
• 18.32. Traction Accelerator
• 18.33. Digital Switch Inputs
• 18.34. Contactors
• 18.35. Contactor Chopping
• 18.36. Fail-Safe
• 18.37. Pump Operation
• 18.38. Pump Speeds and Priorities
• 18.39. Additive Speeds
• 18.40. Power Steer Speed
• 18.41. Pump Inhibit Input
• 18.42. Pump Speed Compensation
• 18.43. Calibration and Adjustments
• 18.44. Traction Personalities (Controller Adjustments)
• 18.45. Traction Status Information
• 18.46. Traction Test Information
• 18.47. BDI Adjustments
• 18.48. Fault Log
• 18.49. Setup Menu (Enables/Disables Features)
• 18.50. Pump Personalities (Controller Adjustments)
• 18.51. Pump Status Information
• 18.52. Pump Test Information
• 18.53. Pump Setup Menu
• 18.54. Traction and Pump Adjustment Descriptions
• 18.55. Setup Menu Descriptions
• 18.56. Controller Connections
• 18.57. Power Connections
• 18.58. Controller Connections
• 18.59. Contactor Connections
• 18.60. Contactor Types
• 18.61. Fuse Ratings
• 18.62. Back Panel Connectors
• 18.63. Connector A – 24 Pin
• 18.64. Connector B – 12 Pin
• 18.65. Connector C – 6 Pin
• 18.66. Controller Area Network (CAN) Overview
• 18.67. Diagnostics
• 18.68. Service and Fault Logs
• 18.69. Service Log
• 18.70. Fault Log
• 18.71. Technical Specifications
• 18.72. Environmental
• 18.73. Mechanical
• 18.74. Electrical
• 18.75. Voltage Specifications
• 18.76. Current Specifications
• 18.77. Miscellaneous Controller Specifications
• 18.78. Contactor Repair
• 18.79. General
• 18.80. Remove Contactor Assembly
• 18.81. Contactor Contacts
• 18.82. Control Switches
• 18.83. Key Switch
• 18.84. Seat Switch
• 18.85. Start Switch
• 18.86. Brake Pedal Adjustment
• 18.87. Accelerator Pedal Adjustment
• 18.88. Table 1. Over- and Undervoltage Protection
• 19. RM0798-(03-2010)-UK-EN
• 19.1. Periodic Maintenance
• 19.2. Safety Precautions Maintenance and Repair
• 19.3. General
• 19.4. How to Move Disabled Lift Truck
• 19.5. How to Tow Lift Truck
• 19.6. How to Put Lift Truck on Blocks
• 19.7. How to Raise Load Wheels
• 19.8. How to Raise Steer Wheels
• 19.9. How to Clean a Lift Truck
• 19.10. Safety Procedures When Working Near Mast
• 19.11. Maintenance Schedule
• 19.12. Maintenance Procedures Every 8 Hours or Daily
• 19.13. Checks Before Operation
• 19.14. Hydraulic System
• 19.15. Battery
• 19.16. Battery Restraint System
• 19.17. Operator Restraint System
• 19.18. Mast, Forks, and Lift Chains
• 19.19. Lift Chain Adjustments
• 19.20. Tires and Wheels
• 19.21. Check Operation
• 19.22. Gauges and Horn
• 19.23. Control Levers and Pedals
• 19.24. Lift System Operation
• 19.25. Service Brakes
• 19.26. Parking Brake
• 19.27. Steering System
• 19.28. Maintenance Procedures Every 500 Hours or 3 Months
• 19.29. Hydraulic Tank Breather
• 19.30. Wheel Nut Torques
• 19.31. Master Drive Unit (MDU)
• 19.32. Lift Chains
• 19.33. Safety Labels
• 19.34. Brake Fluid
• 19.35. Other Lubrication
• 19.36. Electrical Inspection
• 19.37. Contactors
• 19.38. Motor Brushes
• 19.39. Maintenance Procedures Every 2000 Hours or Yearly