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

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Hyster C203 (A1.00-1.50XL) Service Manual - Image 5

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

$30.00

Type Of Manual: Service Manual
Number of Pages: 523
Size: 12.0MB
Format: PDF

Category: Hyster Service Manual PDF

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

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