Hyster C108 (E40-60XL) Service Manual - Image 2

Hyster C108 (E40-60XL) Service Manual - Image 3

Hyster C108 (E40-60XL) Service Manual - Image 4

Hyster C108 (E40-60XL) Service Manual - Image 5

Hyster C108 (E40-60XL) Service Manual

$30.00

Type Of Manual: Service Manual
Number of Pages: 864
Size: 48.9MB
Format: PDF

Category: Hyster Service Manual PDF

Model List:
- C108 (E40-60XL)

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. INTRODUCTION
108.1.1. GENERAL
108.1.2. DESCRIPTION
108.2. REPAIRS
108.2.1. REMOVAL OF THE DRIVE AXLE
108.2.2. CLEANING
108.2.3. INSPECTION
108.2.4. ASSEMBLY
108.2.5. INSTALLATION OF THE DRIVE AXLE ASSEMBLY
108.3. TROUBLESHOOTING
108.4. TORQUE SPECIFICATIONS
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.
110.1. INTRODUCTION
110.1.1. GENERAL
110.1.2. DESCRIPTION
110.2. REPAIRS
110.2.1. STEERING AXLE ASSEMBLY
110.2.2. SPINDLES, BEARINGS, AND TIE RODS
110.2.3. STEERING CYLINDER
110.3. TROUBLESHOOTING
110.4. TORQUE SPECIFICATIONS
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.
112.1. INTRODUCTION
112.1.1. GENERAL
112.1.2. DESCRIPTION AND OPERATION
112.2. REPAIRS
112.2.1. MASTER CYLINDER
112.2.2. BRAKES, E/J1.25-1.75XL(E25-35XL)
112.2.3. BRAKES, E/J2.00-3.00XL (E/J40-60XL)
112.3. SEAT BRAKE
112.3.1. REPAIRS
112.4. SPECIFICATIONS
112.5. TROUBLESHOOTING
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.
119.1. INTRODUCTION
119.1.1. General
119.1.2. Lift Truck Control
119.2. PRINCIPLES OF OPERATION
119.2.1. The Silicon Controlled Rectifier (SCR)
119.2.2. A Motor Circuit That Operates With Pulses
119.2.3. The SCR 1 OFF Circuit
119.2.4. Induction Current From The Motor
119.2.5. The Logic Box
119.2.6. SCR Control (Hydraulic Pump)
119.2.7. Contactors
119.2.8. Circuit Protection
119.2.9. Warning Indicators
119.2.10. Sequence of Operation
120.
120.1. INTRODUCTION
120.1.1. General
120.1.2. Static Return To OFF (SRO) Circuit
120.1.3. Fault Detector
120.1.4. The Sequence of Operation (Traction Circuit)
120.1.5. Checking for the Correct Operation
120.2. TROUBLESHOOTING
120.2.1. General Procedures
120.3. FAULT NEMBER 1. The Direction Contactors Will Not Close For Operation In Either Direction
120.4. FAULT NUMBER 2. The Lift Truck Will Not Move In Either Direction. The Direction Contactors Close and The Immediately Open (72-80
120.5. FAULT NUMBER 2A. The Lift Truck Will Not Move In Either Direction. The Direction Contactors Close and Then Immediately Open (36-
120.6. FAULT NUMBER 3. The Lift Truck Will Not Move In Either Direction. The Direction Contactors Close Normally
120.7. FAULT NUMBER 4. The Lift Truck Will Only Move In One Direction. In The Other Direction, The Direction Contactor Closes And Then
120.8. FAULT NUMBER 5. One Direction Contactor Will Not Close. The Traction Circuit Operates Normally In Only One Direction.
120.9. FAULT NUMBER 6. Contactor 1A Will Not Energize. The Other Operations Of The Lift Truck Are Normal. (36-48 Volt Lift Trucks Equi
120.10. FAULT NUMBER 7. Plugging Problems (Lift Trucks Equipped With Only The Plugging Function)
120.11. FAULT NUMBER 8. Regenerative Braking Problems (Lift Trucks Equipped With Regenerative Braking)
120.12. FAULT NUMBER 9. The Hydraulic Pump Motor Will Not Operate When Any Hydraulic Hand Lever Is Moved From The Neutral Position. (SCR
120.13. FAULT NUMBER 10. The Hydraulic Pump Will Not Stop Operating When The Hydraulic Hand Levers Are Returned To The Neutral Position.
120.14. FAULT NUMBER 11. The Hydraulic Pump Will Not Operate When One Hydraulic Hand Lever Is Moved For A Hydraulic Function. The Operat
120.15. FAULT NUMBER 12. Hydraulic Control Problems (Lift Trucks Equipped With A Hydraulic Pump Contactor)
120.16. REPAIRS AND ADJUSTMENTS
120.16.1. Logic Box
120.16.2. Check the Components of the OFF Circuit
120.16.3. Contactors
120.16.4. Contactor Repair
120.16.5. LED Panel Display
120.16.6. Control Switches
120.16.7. Current Limit
121.
122.
123.
124.
124.1. INTRODUCTION
124.1.1. GENERAL
124.1.2. INDICATORS WITH METER MOVEMENT
124.1.3. BATTERY INDICATORS WITH LCD OR LED DISPLAYS
124.2. CHECKS AND ADJUSTMENTS
124.2.1. BATTERY INDICATORS WITHOUT LIFT INTERRUPT, EARLY MODELS
124.2.2. BATTERY INDICATORS WITH LIFT INTERRUPT, EARLY MODELS
124.2.3. BATTERY INDICATORS WITHOUT LIFT INTERRUPT, LATER MODELS
124.2.4. BATTERY INDICATORS WITH LIFT INTERRUPT, LATER MODELS
124.2.5. LED DISPLAY WITH LIFT INTERRUPT
124.2.6. CHECKING CURTIS 933-1 METER
124.2.7. ADJUSTMENT OF CURTIS 933-1 METER
124.2.8. ADJUSTMENT OF SEVCON POWERGAUGE
124.3. CURTIS DASH DISPLAY ASSEMBLY
124.3.1. Description/Features
124.3.2. Operation
124.3.3. Testing
124.4. REPAIRS
124.4.1. BATTERY INDICATORS
124.4.2. CONTROLLER FOR THE BATTERY INDICATOR
124.4.3. DISPLAY PANEL COMPONENTS
124.4.4. REPLACING SEM DISPLAY PANEL
124.4.5. SEM DISPLAY PANEL REMOVAL
125.
126.
126.1. INTRODUCTION
126.1.1. GENERAL
126.1.2. MAST WELDMENTS
126.1.3. CARRIAGE
126.1.4. MAST MOUNTS
126.2. VISTA TWO-STAGE MAST
126.2.1. DESCRIPTION AND OPERATION
126.3. VISTA FREE-LIFT MAST
126.3.1. DESCRIPTION
126.3.2. OPERATION
126.4. VISTA THREE-STAGE MAST
126.4.1. DESCRIPTION
126.4.2. OPERATION
126.5. VISTA FOUR-STAGE MAST
126.5.1. DESCRIPTION
126.5.2. OPERATION
127.
127.1. VISTA MAST, REPAIR
127.1.1. GENERAL
127.1.2. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
127.1.3. CARRIAGE
127.1.4. SIDE-SHIFT CARRIAGE (EARLIER DESIGN)
127.1.5. SIDE-SHIFT CARRIAGE (1993 AND LATER DESIGN)
127.2. CHECKS AND ADJUSTMENTS
127.2.1. CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM
127.2.2. ADJUST THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE
127.2.3. LIFT CHAIN ADJUSTMENTS
127.2.4. MAST ADJUSTMENTS
127.2.5. CARRIAGE ADJUSTMENT
127.2.6. HEADER HOSE ARRANGEMENTS
127.3. TROUBLESHOOTING
128.
128.1. INTRODUCTION
128.1.1. GENERAL
128.2. REPAIRS
128.2.1. CARRIAGE
128.2.2. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
128.3. CHECKS AND ADJUSTMENTS
128.3.1. CHECK FOR LEAKS IN THE LIFT SYSTEM
128.3.2. ADJUST THE TILT CYLINDER STROKE AND BACKWARD TILT ANGLE
128.3.3. LIFT CHAIN ADJUSTMENTS
128.3.4. MAST ADJUSTMENTS
128.3.5. CARRIAGE ADJUSTMENTS
128.4. TROUBLESHOOTING
129.
129.1. INTRODUCTION
129.1.1. GENERAL
129.1.2. DESCRIPTION AND OPERATION
129.1.3. TWO-STAGE MAST, LIMITED FREE-LIFT
129.1.4. TWO-STAGE MAST, FULL FREE-LIFT
129.1.5. THREE-STAGE, FULL FREE-LIFT MAST
130.
130.1. INTRODUCTION
130.1.1. GENERAL
130.2. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
130.3. REPAIRS
130.3.1. Removal
130.3.2. Installation
130.3.3. CARRIAGES
130.3.4. LIFT CYLINDERS
130.3.5. HEADER HOSE ARRANGEMENTS H/S/E/J2.003.20XM (H/S/E/J4065XM) S/E/J2.003.00XL (S/E/J4060XL)
130.3.6. HEADER HOSE ARRANGEMENTS H/E1.501.75XM, H/S2.00XMS (H/S/E2535XM, H/S/E40XMS) and J1.602.00XMT (J3040XMT)
130.4. CHECKS AND ADJUSTMENTS
130.4.1. CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM
130.4.2. ADJUST THE TILT CYLINDERS
130.4.3. ADJUST THE LIFT CHAINS
130.4.4. ADJUST THE MAST
130.4.5. ADJUST THE CARRIAGE
130.5. TROUBLESHOOTING
131.
132.
132.1. INTRODUCTION
132.1.1. GENERAL
132.1.2. HOW TO MOVE A DISABLED LIFT TRUCK
132.1.3. HOW TO PUT A LIFT TRUCK ON BLOCKS
132.2. MAINTENANCE SCHEDULE
132.3. MAINTENANCE PROCEDURES EVERY 8 HOURS OR DAILY
132.3.1. HOW TO MAKE CHECKS WITH KEY SWITCH OFF
132.3.2. SAFETY LABELS
132.3.3. HOW TO MAKE CHECKS WITH THE KEY SWITCH ON
132.3.4. Steering System
132.4. EVERY 350 HOURS OR TWO MONTHS

Rate this product