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

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

$30.00

Type Of Manual: Service Manual
Number of Pages: 765
Size: 15.3MB
Format: PDF

Category: Hyster Service Manual PDF

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

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