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

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

$30.00

Type Of Manual: Service Manual
Number of Pages: 790
Size: 17.1MB
Format: PDF

Category: Hyster Service Manual PDF

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

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