Hyster F108 (E40-65XM) Service Manual - Image 2

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Hyster F108 (E40-65XM) Service Manual - Image 5

Hyster F108 (E40-65XM) Service Manual

$30.00

Type Of Manual: Service Manual
Number of Pages: 940
Size: 47.8MB
Format: PDF

Category: Hyster Service Manual PDF

Model List:
- F108 (E40-65XM)

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. Main Frame
33. Other Frame Weldments
34. Battery Restraint/Hood Frame And Plate For Optional Seat Brake
35. Overhead Guard
36. REPAIRS
37. OVERHEAD GUARD
38. Removal
39. Installation
40. BATTERY RESTRAINT AND SEAT ASSEMBLY
41. COUNTERWEIGHT
42. Removal
43. Installation
44. TRACTION MOTOR
45. Removal
46. Installation
47. HYDRAULIC TANK
48. Inspection
49. Repairs, Small Leaks
50. Repairs, Large Leaks
51. Cleaning
52. Steam Method Of Cleaning
53. Chemical Solution Method Of Cleaning
54. Additional Preparations For Repair
55. PAINTING INSTRUCTIONS
56. LABEL REPLACEMENT
57. DC Motor Maintenance
58. Safety Precautions Maintenance and Repair
59. General
60. Brush and Commutator Inspection
61. Hydraulic Pump Motor and Traction Motor
62. Steering Pump Motor
63. Normal Commutator Surface
64. Commutator Problems
65. Brush Replacement
66. Stoning the Commutator
67. Motors Repair
68. Disassemble
69. Traction Motor and Hydraulic Pump Motor
70. Steering Pump Motor
71. Assemble
72. Traction Motor and Hydraulic Pump Motor
73. Steering Pump Motor
74. Brush Alignment, Traction and Hydraulic Motors
75. Tests for Damaged Field and Armature
76. Test for an Open Circuit in Armature
77. Test for Short Circuit in One Armature Winding
78. Test for Short Circuit to Armature Shaft
79. Test for Open Circuit in Field Coil
80. Test for Short Circuit in Field Coil
81. Test for Short Circuit between Field and Motor Case
82. Brush Holder Test
83. Troubleshooting
84. Table 1. Normal Commutator Surfaces
85. Table 2. Commutator Problems
86. Table 3. Brush Wear Replacement Guide
87.
87.1. INTRODUCTION
87.2. REPAIRS
87.3. TROUBLESHOOTING
87.4. TORQUE SPECIFICATIONS
88.
88.1. INTRODUCTION
88.2. REPAIRS
88.3. TROUBLESHOOTING
88.4. TORQUE SPECIFICATIONS
89.
89.1. STEERING SYSTEM
89.2. POWER STEERING MOTOR AND PUMP
89.3. HYDRAULIC STEERING MOTOR
89.4. CHECKS AND ADJUSTMENTS
89.5. TROUBLESHOOTING
90.
90.1. INTRODUCTION
90.2. REPAIRS
90.3. CHECKS AND ADJUSTMENTS
90.4. TROUBLESHOOTING
91.
91.1. INTRODUCTION
91.2. REPAIRS
91.3. CHECKS AND ADJUSTMENTS
91.4. TROUBLESHOOTING
92.
92.1. INTRODUCTION
92.2. CHECKS AND ADJUSTMENTS
92.3. TROUBLESHOOTING
92.4. TORQUE SPECIFICATIONS
93.
93.1. INTRODUCTION
93.2. REPAIRS
93.3. CHECKS AND ADJUSTMENTS
93.4. TROUBLESHOOTING CHART
93.5. SPECIFICATIONS
94.
94.1. INTRODUCTION
94.2. REPAIRS
94.3. CHECKS AND ADJUSTMENTS
94.4. TROUBLESHOOTING
95.
96.
96.1. INTRODUCTION
96.2. DESCRIPTION
96.3. CHECKS AND ADJUSTMENTS
96.4. REPLACEMENT
96.5. SPECIFICATIONS
96.6. TROUBLESHOOTING
97.
97.1. ELECTRICAL WARNING DEVICES
98.
99.
99.1. Electrical System
99.2. Safety Precautions Maintenance and Repair
99.3. General
99.4. Description
99.5. ZX Series Display Panels
99.6. Display Panel
99.7. Basic Display Panels
99.8. Performance Display
99.9. Brush Wear Indicators
99.10. SEM Display Panels – Features
99.11. Descriptions of Common Features
99.12. Additional Features of Premium Display Panel
99.13. Descriptions of Additional Features
99.14. SEM Display Panel Indicators
99.15. All Indicator Symbols
99.16. Hourmeter Indicator Symbol
99.17. Wrench Indicator Symbol
99.18. Battery Indicator Symbol
99.19. Battery State-of-Charge (BDI)
99.20. Brake Fluid Too Low Symbol
99.21. Parking Brake Symbol
99.22. Fasten Seat Belt Symbol
99.23. LCD Screen (Standard Display Panel)
99.24. Additional Components of Premium Display Panel
99.25. Alpha Numerical Screen
99.26. STAR Push Button
99.27. Push Buttons 1 Through 5 – SEM
99.28. Other Control Components
99.29. Display Panel Components Replacement
99.30. ZX Panel Replacement
99.31. Display Panel Assembly
99.32. Key Switch, Replace
99.33. Indicator LEDs
99.34. Battery Indicators
99.35. Digital Display (Performance Display Panel Only)
99.36. Status Code or Performance Level Switches and Indicator LEDs (Pe
99.37. Basic Display Panel, Replace Parts
99.38. Performance Display Panel, Replace Parts
99.39. SEM Display Panel Replacement
99.40. Motor Controller (SR or SP) Replacement
99.41. Control Components Replacement
99.42. Start Switch, Replace
99.43. Brake Light Switch, Replace
99.44. Seat Switch, Replace
99.45. External Seat Switch, Adjust
99.46. Switch for Optional Seat Brake, Replace
99.47. Parking Brake Switch, Replace
99.48. Direction Switches (MONOTROL Pedal), Replace
99.49. Direction Control Switches (Steering Column), Replace
99.50. Direction Control Switches, E70-120XL 3 (Steering Column)
99.51. Brake Fluid Switch, Replace
99.52. Brush Wear and Overtemperature Sensors
99.53. Rocker Switches for Lights
99.54. Accelerator Position Sensor, Replace
99.55. On-Demand Steering Components
99.56. Lights, Converter, Relay, and Reverse Alarm
99.57. Brake, Tail, and Reverse Light Assembly, Replace
99.58. Flashing Light Assembly, Replace
99.59. Front, Rear Driving Light, or Spot Light Assemblies, Replace
99.60. Operator Compartment Light Assembly, Replace
99.61. Converter, Replace
99.62. Relay, Replace
99.63. Reverse Alarm, Replace
99.64. Horn and Horn Button
99.65. Horn Switch and Cover
99.66. Hydraulic Pump Switches
99.67. Control and Power Fuses Check
99.68. Brush Wear and Overtemperature Sensors Check – ZX
99.69. Thermal Sensors – SEM Check
99.70. Start Switch Adjustment
99.71. Accelerator Potentiometer and Start Switch E70-120XL, E70-120XL
99.72. E70-120XL
99.73. E70-120XL 3
99.74. Direction Switches (MONOTROL)
99.75. Brake Light Switch Adjustment
99.76. Seat Switch Check
99.77. Optional Seat Brake Switch Adjustment
99.78. Parking Brake Switch Adjustment
99.79. Direction Switches Check
99.80. Monotrol Pedal
99.81. Steering Column
99.82. Hydraulic Pump Switch Adjustment
99.83. MONOTROL or Accelerator Pedal Adjustment
99.84. Accelerator Position Sensor Adjustment
100.
101.
102.
102.1. EV-100 TRANSISTOR MOTOR CONTROLLER, Parameter Tables
103.
103.1. TROUBLESHOOTING AND ADJUSTMENTS WITH A COMPUTER For EV-100ZX, EV-T100, SR (SEM) And SP Motor Controllers
104.
105.
106.
106.1. INTRODUCTION
107.
107.1. INTRODUCTION
107.2. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
107.3. REPAIRS
107.4. CHECKS AND ADJUSTMENTS
107.5. TROUBLESHOOTING
108.
108.1. INTRODUCTION
108.2. REPAIRS
108.3. CHECKS AND ADJUSTMENTS
108.4. TROUBLESHOOTING
109.
110.
111.
111.1. INTRODUCTION
111.2. MAINTENANCE SCHEDULE
111.3. MAINTENANCE PROCEDURES
111.4. EVERY 8 HOURS OR DAILY
111.5. EVERY 350 HOURS OR THREE MONTHS
111.6. EVERY 2000 HOURS OR YEARLY
111.7. GENERAL PROCEDURE
111.8. REFERENCE TABLE
112.
112.1. COUNTERWEIGHTS
112.2. HYDRAULIC SYSTEM
112.3. WHEELS AND TIRES
112.4. BATTERY SPECIFICATIONS – E2.00-3.20XM (E45-65XM, E45-XM2, N30XMH, N30XMH2)
112.5. BATTERY SPECIFICATIONS – J2.00-3.20XM (J40-65XM, J40-65XM2)
112.6. CAPACITIES
112.7. MOVEMENT RATES (MAXIMUM) FOR TILT CYLINDERS
112.8. E45-65XM MAST SPEEDS (36 or 48 Volt) Americas
112.9. E40-65XM, E40-65XM2, N30XMH2 MAST SPEEDS (36 or 48 Volt) (3/99) Americas
112.10. E2.00-3.20XM MAST SPEEDS (72 or 80 Volt) Europe
112.11. E2.00-3.20XM MAST SPEEDS (72 or 80 Volt) Europe
112.12. E2.00-3.20XM, E2.00-3.20XM2, MAST SPEEDS (72 or 80 Volt) (3/99) Europe
112.13. J40-65XM MAST SPEEDS (36 or 48 Volt) Americas
112.14. J40-65XM, J40-65XM2, MAST SPEEDS (36 or 48 Volt) (3/99) Americas
112.15. J2.00-3.20XM MAST SPEEDS (72 or 80 Volt) Europe
112.16. J2.00-3.20XM MAST SPEEDS (72 or 80 Volt) (3/99) Europe
112.17. TORQUE SPECIFICATIONS
112.18. REFERENCE TABLE
113.
113.1. FIGURE 1. J2.00-3.200XM TRANSISTOR CONTROLLERS FOR TRACTION MOTOR AND HYDRAULIC PUMP MOTORS
113.2. FIGURE 2. E1.50-3.20XMS TRANSISTOR CONTROLLERS FOR TRACTION MOTOR AND HYDRAULIC PUMP MOTORS
113.3. FIGURE 3. SCHEMATIC DIAGRAM, TRANSISTOR CONTROLLERS FOR TRACTION MOTOR AND HYDRAULIC PUMP MOTORS
113.4. FIGURE 4. WIRING DIAGRAM, J2.00-3.20XM TRANSISTOR CONTROLLERS FOR TRACTION MOTOR AND HYDRAULIC PUMP MOTORS
113.5. FIGURE 5. WIRING DIAGRAM, J2.00-3.20XM TRANSISTOR CONTROLLER FOR TRACTION MOTOR, CONTACTOR CONTROLLER FOR HYDRAULIC PUMP
113.6. FIGURE 6. WIRING DIAGRAM, E1.50-3.20XMS TRANSISTOR CONTROLLERS FOR TRACTION MOTOR AND HYDRAULIC PUMP MOTORS
113.7. FIGURE 7. WIRING DIAGRAM, E1.50-3.20XMS TRANSISTOR CONTROLLER FOR TRACTION MOTOR, CONTACTOR CONTROL FOR HYDRAULIC PUMP
113.8. FIGURE 8. WIRE HARNESS, J2.00-3.20XM
113.9. FIGURE 9. POWER CABLES AND BATTERY CONNECTOR, J2.00-3.20XM
113.10. FIGURE 10. E1.50-3.20XM TRUCK WIRING
113.11. FIGURE 11. TRUCK POWER CABLES
113.12. FIGURE 12. TRUCK POWER CABLES
113.13. FIGURE 13. HYDRAULIC LINKAGE SWITCH AND CHASSIS WIRING DETAILS
113.14. FIGURE 14. WIRING SCHEMATIC FOR THE INSTRUMENT PANEL, E/J2.00-3.20XM
113.15. FIGURE 15. DISPLAY PANELS AND PLUG CONNECTIONS
113.16. FIGURE 16. CONFIGURATION OF THE EV-T100 MOTOR CONTROLLER MODULE
113.17. FIGURE 17. CONTROL CARD CONNECTIONS
113.18. FIGURE 18. TRUCK MANAGEMENT MODULE (TMM1)
113.19. FIGURE 19. WIRING SCHEMATIC, E2.00-3.20XM TRANSISTOR CONTROLLERS FOR TRACTION MOTOR AND HYDRAULIC PUMP MOTORS
113.20. FIGURE 20. DETAIL OF BATTERY CONNECTOR WITH 12 VOLT TAP
113.21. FIGURE 21. HYDRAULIC SCHEMATIC, E/J2.00-3.20XM E1.50-2.00XMS
113.22. FIGURE 22. WIRING DIAGRAM FOR LIGHTS

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