Hyster C098 (E70-120XL) Service Manual - Image 2

Hyster C098 (E70-120XL) Service Manual - Image 3

Hyster C098 (E70-120XL) Service Manual - Image 4

Hyster C098 (E70-120XL) Service Manual - Image 5

Hyster C098 (E70-120XL) Service Manual

$30.00

Type Of Manual: Service Manual
Number of Pages: 740
Size: 36.1MB
Format: PDF

Category: Hyster Service Manual PDF

Model List:
- C098 (E70-120XL)

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. GENERAL
30. DESCRIPTION
31. BATTERY SPECIFICATIONS
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, Small 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 PLACEMENT
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. DC Motor Maintenance
79. Safety Precautions Maintenance and Repair
80. General
81. Brush and Commutator Inspection
82. Hydraulic Pump Motor and Traction Motor
83. Steering Pump Motor
84. Normal Commutator Surface
85. Commutator Problems
86. Brush Replacement
87. Stoning the Commutator
88. Motors Repair
89. Disassemble
90. Traction Motor and Hydraulic Pump Motor
91. Steering Pump Motor
92. Assemble
93. Traction Motor and Hydraulic Pump Motor
94. Steering Pump Motor
95. Brush Alignment, Traction and Hydraulic Motors
96. Tests for Damaged Field and Armature
97. Test for an Open Circuit in Armature
98. Test for Short Circuit in One Armature Winding
99. Test for Short Circuit to Armature Shaft
100. Test for Open Circuit in Field Coil
101. Test for Short Circuit in Field Coil
102. Test for Short Circuit between Field and Motor Case
103. Brush Holder Test
104. Troubleshooting
105. Table 1. Normal Commutator Surfaces
106. Table 2. Commutator Problems
107. Table 3. Brush Wear Replacement Guide
108.
108.1. DRIVE AXLE
108.1.1. GENERAL
108.1.2. DESCRIPTION
108.2. REPAIRS
108.2.1. REMOVAL
108.2.2. DISASSEMBLY
108.2.3. CLEANING
108.2.4. INSPECTION
108.2.5. ASSEMBLY
108.2.6. ADJUSTMENTS OF SHIMS FOR THE PINION ASSEMBLY
108.2.7. DRIVE AXLE HOUSING
108.3. TROUBLESHOOTING
109.
109.1. STEERING CONTROL UNIT
109.1.1. GENERAL
109.1.2. DESCRIPTION
109.1.3. DISASSEMBLY AND INSPECTION
109.1.4. ASSEMBLY
109.2. TROUBLESHOOTING
110.
111.
111.1. STEERING SYSTEM
111.1.1. GENERAL
111.1.2. DESCRIPTION
111.1.3. STEERING WHEEL AND COLUMN ASSEMBLY
111.2. POWER STEERING MOTOR AND PUMP
111.2.1. DESCRIPTION
111.2.2. REMOVAL AND DISASSEMBLY, E1.25-3.00XL (E25-60XL), J2.00-3.00XL (J40-60XL), E2.00-3.20XM (E45-65XM)
111.2.3. REMOVAL AND DISASSEMBLY, E3.50-5.50XL (E70-120XL, E70-120XL3)
111.2.4. REMOVAL AND DISASSEMBLY, J2.00-3.20XM (J40-65XM)
111.2.5. REMOVAL AND DISASSEMBLY, A1.00-1.50XL (A20-30XL)
111.2.6. REMOVAL AND DISASSEMBLY, E1.50-2.00XMS (E25-40XMS)
111.2.7. ASSEMBLY AND INSTALLATION All models with a verticle mount except the J2.00-3.20XM (J40-65M)
111.2.8. ASSEMBLY AND INSTALLATION, J2.00-3.20XM (J40-65XM)
111.2.9. ASSEMBLY AND INSTALLATION, E1.50-2.00XMS (E25-40XMS)
111.2.10. REPAIRS, POWER STEERING PUMP
111.3. HYDRAULIC STEERING MOTOR
111.3.1. DESCRIPTION
111.3.2. REPAIRS, HYDRAULIC STEERING MOTOR
111.4. CHECKS AND ADJUSTMENTS
111.4.1. AIR IN THE STEERING SYSTEM
111.4.2. CHECK STEERING PRESSURE
111.4.3. CHECK THE TENSION OF THE STEERING CHAIN (Units With MDU Only)
111.4.4. CHECK OPTIONAL ENCODER AND ACTIVATOR CIRCUITS
111.5. TROUBLESHOOTING
112.
113.
113.1. HYDRAULIC SYSTEM
113.1.1. GENERAL
113.1.2. DESCRIPTION
113.1.3. OPERATION
113.2. REPAIRS
113.2.1. HYDRAULIC PUMP
113.3. CHECKS AND ADJUSTMENTS
113.3.1. MAIN CONTROL VALVE
113.3.2. STEERING RELIEF VALVE
113.4. TROUBLESHOOTING
113.5. SPECIFICATIONS
114.
115.
115.1. INTRODUCTION
115.1.1. GENERAL
115.2. DESCRIPTION
115.2.1. GENERAL
115.2.2. STEERING COLUMN GAUGES, METERS AND INDICATORS
115.2.3. LED DISPLAY PANEL
115.2.4. LX SERIES DISPLAY PANEL
115.2.5. ZX SERIES DISPLAY PANELS
115.3. CHECKS AND ADJUSTMENTS
115.3.1. GENERAL
115.4. REPLACEMENT
115.4.1. GENERAL
115.4.2. METER REPLACEMENT
115.4.3. SENDER REPLACEMENT
115.4.4. DISPLAY PANEL
115.4.5. DISPLAY PANELS FOR THE EV – 100/200ZX MOTOR CONTROLLERS, COLUMN MOUNT
115.4.6. DISPLAY PANELS FOR THE EV-100/200ZX MOTOR CONTROLLERS, DASH MOUNT
115.5. SPECIFICATIONS
115.6. TROUBLESHOOTING
116.
116.1. ELECTRICAL WARNING DEVICES
116.1.1. GENERAL
116.1.2. DESCRIPTION
116.1.3. REPLACEMENT
117.
118.
119.
120.
120.1. INTRODUCTION
120.1.1. GENERAL
120.2. SEQUENCE OF OPERATION
120.3. CHECKS AND REPAIRS
120.3.1. GENERAL
120.3.2. THE CONTROL CARD PLUGS
120.3.3. HOW TO CHECK AN SCR
120.3.4. THE OFF CIRCUIT FOR SCR 1
120.3.5. DIODES D3 and D4
120.3.6. MOTOR CURRENT SENSOR
120.3.7. THE ELECTRONIC DRIVER MODULE
120.3.8. CONTACTORS
120.3.9. Contactor Repair
120.3.10. CHECK THE PMT CIRCUIT
120.4. ADJUSTMENTS
120.4.1. CONTROL CARD ADJUSTMENTS
120.4.2. SCR CONTROL, DUAL HYDRAULIC PUMP MOTORS
120.4.3. VOLTAGE ADJUSTMENTS, SCR CONTROL FOR HYDRAULIC PUMP
121.
122.
123.
123.1. INTRODUCTION
123.1.1. GENERAL
123.1.2. INDICATORS WITH METER MOVEMENT
123.1.3. BATTERY INDICATORS WITH LCD OR LED DISPLAYS
123.2. CHECKS AND ADJUSTMENTS
123.2.1. BATTERY INDICATORS WITHOUT LIFT INTERRUPT, EARLY MODELS
123.2.2. BATTERY INDICATORS WITH LIFT INTERRUPT, EARLY MODELS
123.2.3. BATTERY INDICATORS WITHOUT LIFT INTERRUPT, LATER MODELS
123.2.4. BATTERY INDICATORS WITH LIFT INTERRUPT, LATER MODELS
123.2.5. LED DISPLAY WITH LIFT INTERRUPT
123.2.6. CHECKING CURTIS 933-1 METER
123.2.7. ADJUSTMENT OF CURTIS 933-1 METER
123.2.8. ADJUSTMENT OF SEVCON POWERGAUGE
123.3. CURTIS DASH DISPLAY ASSEMBLY
123.3.1. Description/Features
123.3.2. Operation
123.3.3. Testing
123.4. REPAIRS
123.4.1. BATTERY INDICATORS
123.4.2. CONTROLLER FOR THE BATTERY INDICATOR
123.4.3. DISPLAY PANEL COMPONENTS
123.4.4. REPLACING SEM DISPLAY PANEL
123.4.5. SEM DISPLAY PANEL REMOVAL
124.
125.
125.1. VISTA MASTS
125.1.1. GENERAL
125.1.2. DESCRIPTION AND OPERATION
125.1.3. CARRIAGES
125.1.4. TWO-STAGE MAST WITH LIMITED FREE-LIFT
125.1.5. TWO-STAGE MAST WITH FULL FREE-LIFT MAST
125.1.6. THREE-STAGE MAST WITH FULL FREE-LIFT
125.2. REPAIRS
125.2.1. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST (1 of 2)
125.2.2. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST (2 of 2)
125.2.3. CARRIAGE
125.2.4. SIDE-SHIFT CARRIAGE (EARLIER DESIGNS)
125.2.5. SIDE-SHIFT CARRIAGE (1993 AND LATER DESIGNS)
125.2.6. WEIGHT OF MAST PARTS
125.2.7. TWO-STAGE MAST WITH LIMITED FREE LIFT
125.2.8. TWO-STAGE MAST WITH FULL FREE-LIFT
125.2.9. THREE-STAGE MAST WITH FULL FREE LIFT
125.3. CHECKS AND ADJUSTMENTS
125.3.1. CHECK THE OPERATION OF THE MAST
125.3.2. CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM
126.
127.
127.1. INTRODUCTION
127.1.1. GENERAL
127.1.2. HOW TO MOVE A DISABLED LIFT TRUCK
127.1.3. HOW TO PUT A LIFT TRUCK ON BLOCKS
127.2. MAINTENANCE SCHEDULE
127.3. MAINTENANCE PROCEDURES EVERY 8 HOURS OR DAILY
127.3.1. HOW TO MAKE CHECKS WITH KEY SWITCH OFF
127.3.2. SAFETY LABELS
127.3.3. HOW TO MAKE CHECKS WITH THE KEY SWITCH ON
127.3.4. Steering System
127.4. EVERY 350 HOURS OR TWO MONTHS
127.4.1. HYDRAULIC TANK BREATHER
127.4.2. STEERING TIE RODS, E/J1.25-1.75XL (E25-35XL) and J2.00-3.00XL (J40-60XL)
127.4.3. DIFFERENTIAL AND SPEED REDUCER
127.4.4. WHEEL NUT TORQUES
127.4.5. STEERING AXLE SPINDLES, E/J2.00-3.00XL (E/J40-60XL) E3.50-5.50XL (E70-120XL)
127.4.6. LIFT CHAINS
127.4.7. BRAKE FLUID
127.4.8. OTHER LUBRICATION
127.4.9. SEAT BRAKE
127.4.10. ELECTRICAL INSPECTION
127.5. EVERY 2000 HOURS OR YEARLY
127.5.1. HYDRAULIC SYSTEM
127.5.2. DIFFERENTIAL AND SPEED REDUCER
127.5.3. SERVICE BRAKES
127.5.4. CONTACTORS
127.5.5. WHEEL BEARINGS
127.5.6. LIFT CHAINS
127.6. GENERAL PROCEDURES
127.6.1. HOW TO CHARGE THE BATTERY
127.6.2. HOW TO CHANGE THE BATTERY
127.6.3. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
127.6.4. CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM
127.6.5. LIFT CHAIN ADJUSTMENTS
127.6.6. HOW TO CHECK THE PMT CIRCUIT
127.6.7. WELDING REPAIRS
127.6.8. CHANGE THE OVERHEAD GUARD
127.7. WHEELS AND TIRES
127.7.1. GENERAL
127.7.2. SOLID RUBBER TIRES (PRESS-ON)
127.7.3. PNEUMATIC TIRES
127.7.4. Install The Wheels
127.7.5. SOLID RUBBER TIRES THAT LOOK LIKE PNEUMATIC TIRES
127.8. SPECIFICATIONS
127.9. REFERENCE TABLE
128.
129.
129.1. FIGURE 1. SCHEMATIC DIAGRAM, EV100 OR EV200 SCR TRACTION MOTOR CONTROL, 3648 VOLTS
129.2. FIGURE 2. WIRING DIAGRAM, EV100 SCR TRACTION MOTOR CONTROL WITH SINGLE OR DUAL HYDRAULIC PUMP MOTOR CONTACTOR CONTROL
129.3. FIGURE 3. WIRING DIAGRAM, EV200 SCR TRACTION MOTOR CONTROL WITH EV100 SCR HYDRAULIC PUMP MOTOR CONTROL
129.4. FIGURE 4. WIRING DIAGRAM, CONTROL SWITCHES
129.5. FIGURE 5. HYDRAULIC PUMP MOTOR CONTROLS (1 OF 3)
129.6. FIGURE 6. BATTERY INDICATORS
129.7. FIGURE 7. HYDRAULIC SCHEMATIC
129.8. FIGURE 8. SCHEMATIC AND WIRING DIAGRAM 12V LIGHTS
130.
130.1. FIGURE 1. SCHEMATIC DIAGRAM, EV-100 OR EV-200 SCR TRACTION MOTOR CONTROL, 36-48 VOLTS
130.2. FIGURE 2. WIRING DIAGRAM, EV-100 SCR TRACTION MOTOR CONTROL WITH SINGLE OR DUAL HYDRAULIC PUMP MOTOR CONTACTOR CONTROL
130.3. FIGURE 3. WIRING DIAGRAM, EV-200 SCR TRACTION MOTOR CONTROL WITH EV-100 SCR HYDRAULIC PUMP MOTOR CONTROL
130.4. FIGURE 4. WIRING DIAGRAM, CONTROL SWITCHES (1 OF 2)
130.5. FIGURE 5. HYDRAULIC PUMP MOTOR CONTROLS (1 OF 4)
130.6. FIGURE 6. EV-100 LX SERIES GE OR ITW DISPLAY WITH LIFT INTERRUPT – WITHOUT PUMP MOTOR SCR CONTROL SCHEMATIC
130.7. FIGURE 7. BATTERY INDICATORS
131.
131.1. FIGURE 1. HYDRAULIC SCHEMATIC
131.2. FIGURE 2. SCHEMATIC DIAGRAM, EV-100ZX OR EV-200ZX SCR MOTOR CONTROLLERS, 36-48 VOLTS
131.3. FIGURE 3. WIRING DIAGRAM, EV-100ZX OR EV-200ZX SCR MOTOR CONTROLLERS, 36-48 VOLTS
131.4. FIGURE 4. CABLE DIAGRAM, EV-100ZX OR EV200-ZX SCR MOTOR CONTROLLERS, 36-48 VOLTS
131.5. FIGURE 5. DETAIL DIAGRAM, EV-100ZX OR EV-200ZX SCR MOTOR CONTROLLERS, 36-48 VOLTS
131.6. FIGURE 6. CONTROL PANELS, EV100ZX OR EV-200ZX SCR MOTOR CONTROLLERS, 36-48 VOLTS
131.7. FIGURE 7. SCHEMATIC AND WIRING DIAGRAM – 12V LIGHTS

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