Hyster C203 (A1.00-1.50XL A20-30XL) Service Manual – PDF DOWNLOAD

Description

Hyster C203 (A1.00-1.50XL A20-30XL) Service Manual – PDF DOWNLOAD

DESCRIPTION:

Hyster C203 (A1.00-1.50XL A20-30XL) Service Manual – PDF DOWNLOAD

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair
on electric lift trucks.
• Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance
section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit whenmaking repairs,
or if the unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.

TABLE OF CONTENTS:

Hyster C203 (A1.00-1.50XL A20-30XL) Service Manual – PDF DOWNLOAD

0100SRM793-1482603(03-2000)-EN........................................................................................  1
	toc...............................................................................................................  1
		Frame.........................................................................................................  1
		Safety Precautions Maintenance and Repair.....................................................................  2
		General.......................................................................................................  5
		Description...................................................................................................  5
		Overhead Guard Repair.........................................................................................  6
			Remove....................................................................................................  6
			Install...................................................................................................  6
		Hood and Seat Assembly Repair.................................................................................  6
			Remove....................................................................................................  8
			Install...................................................................................................  8
		Counterweight Repair..........................................................................................  8
			Remove....................................................................................................  8
			Install...................................................................................................  9
		Hydraulic Tank Repair......................................................................................... 10
			Inspect................................................................................................... 10
			Small Leaks, Repair....................................................................................... 10
			Large Leaks, Repair....................................................................................... 10
			Clean..................................................................................................... 10
				Steam Method.......................................................................................... 10
				Chemical Solution Method.............................................................................. 11
			Additional Preparations for Repair........................................................................ 11
		Safety Labels................................................................................................. 11
		Battery Specifications........................................................................................ 14
	tables............................................................................................................  1
		Table 1. Weight of Counterweights.............................................................................  9
0620SRM145-899769(02-1997)-EN......................................................................................... 17
	INTRODUCTION...................................................................................................... 17
	MAGNETISM......................................................................................................... 17
		MAGNETISM AND PERMANENT MAGNETS............................................................................... 17
		ELECTROMAGNETIC FIELDS........................................................................................ 17
		ELECTROMAGNETS................................................................................................ 18
		ELECTROMAGNETIC INDUCTION..................................................................................... 19
		MAGNETIC FORCE ON A CONDUCTOR................................................................................. 19
	BASIC MOTORS...................................................................................................... 20
		MOTOR OPERATION............................................................................................... 20
		COMMUTATION PRINCIPLE......................................................................................... 21
		DIRECTION OF MOTOR ROTATION................................................................................... 21
		MOTOR SPEED................................................................................................... 21
		MOTOR TORQUE.................................................................................................. 22
		COUNTER ELECTROMOTIVE FORCE................................................................................... 22
		TYPICAL MOTOR................................................................................................. 22
		TYPES OF MOTORS............................................................................................... 22
			Permanent–Magnet.......................................................................................... 22
			Series Wound.............................................................................................. 23
			Parallel or Shunt Wound................................................................................... 24
			Compound Wound............................................................................................ 24
		MOTOR INSULATION CLASS........................................................................................ 25
		STORAGE....................................................................................................... 25
		HANDLING...................................................................................................... 25
		BREAK–IN OPERATION............................................................................................ 25
		CLEANING...................................................................................................... 26
		BASIC REPAIR GUIDELINES....................................................................................... 26
		BEARINGS, SEALS AND LUBRICATION............................................................................... 27
		BRUSHES AND BRUSH HOLDERS..................................................................................... 27
		ARMATURE...................................................................................................... 28
		COMMUTATOR.................................................................................................... 28
			Description............................................................................................... 28
		SATISFACTORY SURFACE.......................................................................................... 29
		STREAKING AND THREADING SURFACE............................................................................... 30
		GROOVING ON SURFACE........................................................................................... 31
		COPPER DRAG ON SURFACE........................................................................................ 33
		OVERHEATING................................................................................................... 33
		FIELD ASSEMBLY................................................................................................ 35
		INSPECTION CHECKLIST.......................................................................................... 35
		CHECKING AND REPLACING MOTOR BRUSHES.......................................................................... 35
			Inspecting Brushes........................................................................................ 35
		INSPECT THE COMMUTATOR........................................................................................ 36
		REPLACING BRUSHES............................................................................................. 36
		SEATING BRUSHES (STONING PROCEDURE)........................................................................... 36
		CHECK THE MOTORS FOR OPENS, GROUNDS AND SHORTS................................................................ 37
			Check The Motor For Opens................................................................................. 37
			Check The Motor For Grounds............................................................................... 37
			Check The Motor For Shorts................................................................................ 37
		COMMUTATOR INSPECTION......................................................................................... 39
		POLISHING COMMUTATOR.......................................................................................... 40
		TURNING COMMUTATOR............................................................................................ 40
		UNDERCUTTING COMMUTATOR....................................................................................... 40
		SLOT RAKING AND BRUSHING COMMUTATOR........................................................................... 40
0620SRM294-897076(03-2003)-EN......................................................................................... 42
	toc............................................................................................................... 42
		DC Motor Maintenance.......................................................................................... 42
		Safety Precautions Maintenance and Repair..................................................................... 43
		General....................................................................................................... 46
		Brush and Commutator Inspection............................................................................... 46
			Hydraulic Pump Motor and Traction Motor................................................................... 46
			Steering Pump Motor....................................................................................... 49
			Normal Commutator Surface................................................................................. 49
			Commutator Problems....................................................................................... 49
		Brush Replacement............................................................................................. 53
		Stoning the Commutator........................................................................................ 55
		Motors Repair................................................................................................. 57
			Disassemble............................................................................................... 57
				Traction Motor and Hydraulic Pump Motor............................................................... 57
				Steering Pump Motor................................................................................... 59
			Assemble.................................................................................................. 61
				Traction Motor and Hydraulic Pump Motor............................................................... 61
				Steering Pump Motor................................................................................... 62
		Brush Alignment, Traction and Hydraulic Motors................................................................ 64
		Tests for Damaged Field and Armature.......................................................................... 64
			Test for an Open Circuit in Armature...................................................................... 64
			Test for Short Circuit in One Armature Winding............................................................ 65
			Test for Short Circuit to Armature Shaft.................................................................. 65
			Test for Open Circuit in Field Coil....................................................................... 65
			Test for Short Circuit in Field Coil...................................................................... 66
			Test for Short Circuit between Field and Motor Case....................................................... 66
			Brush Holder Test......................................................................................... 66
		Troubleshooting............................................................................................... 66
	tables............................................................................................................ 42
		Table 1. Normal Commutator Surfaces........................................................................... 48
		Table 2. Commutator Problems.................................................................................. 49
		Table 3. Brush Wear Replacement Guide......................................................................... 53
0630SRM794-1482607(05-2000)-EN........................................................................................ 72
	toc............................................................................................................... 72
		Master Drive Unit (ZF)........................................................................................ 72
		Safety Precautions Maintenance and Repair..................................................................... 73
		General....................................................................................................... 76
		Description................................................................................................... 76
			Top Section Housing....................................................................................... 76
			Transmission Housing...................................................................................... 76
		Repair........................................................................................................ 77
			Remove.................................................................................................... 77
			Disassemble............................................................................................... 78
				Top Section Housing................................................................................... 78
				Transmission Housing.................................................................................. 81
			Assemble.................................................................................................. 83
				Installing Spiral Bevel Pinion Shaft.................................................................. 83
				Measuring Bearing Movement in Bevel Pinion Shaft...................................................... 85
				Assembly of Helical Gear.............................................................................. 86
				Assembling Crown Gear and Wheel Shaft................................................................. 86
				Assembling Transmission Housing Cover................................................................. 88
				Assembling Input Motor Pinion Gear.................................................................... 88
				Inspecting Top Section Housing........................................................................ 88
				Measuring Pivoting Bearing Movement................................................................... 89
				Installing Top Section Housing........................................................................ 89
			Install................................................................................................... 90
		Tooth Contact Pattern Adjustment.............................................................................. 91
		Changing Transmission Oil..................................................................................... 92
		Troubleshooting............................................................................................... 93
	tables............................................................................................................ 72
		Table 1. Tooth Contact Pattern................................................................................ 91
0630SRM795-1482613(04-2000)-EN........................................................................................ 98
	toc............................................................................................................... 98
		Master Drive Unit (Kordel).................................................................................... 98
		Safety Precautions Maintenance and Repair..................................................................... 99
		General.......................................................................................................102
		Description...................................................................................................102
			Upper Section.............................................................................................102
			Lower Section.............................................................................................104
		Drive Unit Repair.............................................................................................104
			Remove....................................................................................................104
			Disassemble...............................................................................................105
			Assemble..................................................................................................108
				General...............................................................................................108
				Assemble Component Subassemblies......................................................................108
				Assemble Components Into Lower Section................................................................108
				Assemble Upper and Lower Sections.....................................................................109
			Install...................................................................................................109
		Check and Change Transmission Oil.............................................................................110
		Tooth Contact Pattern Adjustment..............................................................................111
		Troubleshooting...............................................................................................112
	tables............................................................................................................ 98
		Table 1. Tooth Contact Pattern................................................................................111
1600SRM485-897450(05-1996)-EN.........................................................................................116
	STEERING SYSTEMS FOR ELECTRICAL LIFT TRUCKS.......................................................................116
		GENERAL.......................................................................................................116
		DESCRIPTION...................................................................................................118
		STEERING WHEEL AND COLUMN ASSEMBLY............................................................................119
			Removal Of The Assembly Components........................................................................119
			Installation Of The Assembly Components...................................................................123
	POWER STEERING MOTOR AND PUMP.....................................................................................124
		DESCRIPTION...................................................................................................124
		REMOVAL AND DISASSEMBLY, E1.25-3.00XL (E25-60XL), J2.00-3.00XL (J40-60XL), E2.00-3.20XM (E45-65XM), N30XMH....124
		REMOVAL AND DISASSEMBLY, E3.50-5.50XL (E70-120XL).............................................................124
		REMOVAL AND DISASSEMBLY, J2.00-3.20XM (J40-65XM)..............................................................125
		REMOVAL AND DISASSEMBLY, A1.00-1.50XL (A20-30XL)..............................................................127
		REMOVAL AND DISASSEMBLY, E1.50-2.00XMS (E25-40XMS)............................................................128
		ASSEMBLY AND INSTALLATION {All models with a vertical mount except the J2.00-3.20XM (J40-65XM)}...............128
		ASSEMBLY AND INSTALLATION, J2.00-3.20XM (J40-65XM)............................................................128
		ASSEMBLY AND INSTALLATION, E1.50-2.00XMS (25-40XMS)...........................................................131
		REPAIRS, POWER STEERING PUMP..................................................................................132
			Seal Replacement..........................................................................................133
	HYDRAULIC STEERING MOTOR..........................................................................................133
		DESCRIPTION...................................................................................................133
		REPAIRS, HYDRAULIC STEERING MOTOR.............................................................................134
			Removal...................................................................................................134
			Disassembly ..............................................................................................134
			Cleaning And Inspection...................................................................................134
			Assembly..................................................................................................135
			Installation, Hydraulic Steering Motor....................................................................136
	CHECKS AND ADJUSTMENTS............................................................................................136
		AIR IN THE STEERING SYSTEM....................................................................................136
		CHECK STEERING PRESSURE.......................................................................................136
		CHECK THE TENSION OF THE STEERING CHAIN (Units With MDU Only).................................................138
		CHECK OPTICAL ENCODER AND ACTIVATOR CIRCUITS..................................................................138
	TROUBLESHOOTING...................................................................................................140
1600SRM796-1482620(03-2000)-EN........................................................................................142
	toc...............................................................................................................142
		Steering System...............................................................................................142
		Safety Precautions Maintenance and Repair.....................................................................143
		General.......................................................................................................146
		Description...................................................................................................146
			Steering Wheel and Column Assembly........................................................................147
		Steering Control Unit Repair..................................................................................151
			Remove....................................................................................................151
			Install...................................................................................................151
		Hydraulic Steering Motor Repair...............................................................................152
			Description...............................................................................................152
			Remove....................................................................................................152
			Disassemble...............................................................................................152
			Clean and Inspect.........................................................................................154
			Assemble..................................................................................................154
			Install...................................................................................................155
		Direction Control Lever Repair................................................................................155
			Remove....................................................................................................155
			Assemble..................................................................................................156
			Install...................................................................................................156
		Power Steering Adjustments....................................................................................156
			Air in Steering System....................................................................................156
			Steering Pressure.........................................................................................156
			Steering Chain, Adjust....................................................................................157
		Troubleshooting...............................................................................................157
1600SRM797-1482617(03-2000)-EN........................................................................................162
	toc...............................................................................................................162
		Steering Control Unit.........................................................................................162
		Safety Precautions Maintenance and Repair.....................................................................163
		General.......................................................................................................166
		Description...................................................................................................166
		Operation.....................................................................................................166
		Steering Wheel and Column Assembly Repair.....................................................................168
		Steering Column Assembly Repair...............................................................................169
			Remove and Disassemble....................................................................................169
			Assemble and Install......................................................................................169
			Steering Control Unit, Disassemble........................................................................170
			Steering Control Unit, Clean..............................................................................172
			Steering Control Unit, Assemble...........................................................................173
		System Air Removal............................................................................................176
		Troubleshooting...............................................................................................177
1800SRM803-1482623(03-2000)-EN........................................................................................182
	toc...............................................................................................................182
		Brake System..................................................................................................182
		Safety Precautions Maintenance and Repair.....................................................................183
		General.......................................................................................................186
		Description and Operation.....................................................................................186
		Master Cylinder Repair........................................................................................188
			Remove and Disassemble....................................................................................188
			Clean and Inspect.........................................................................................189
			Assemble and Install......................................................................................189
		Service and Parking Brakes Repair.............................................................................190
			Remove and Disassemble....................................................................................190
			Clean.....................................................................................................191
			Inspect...................................................................................................191
			Assemble and Install......................................................................................192
		Brake System Air Removal......................................................................................192
		Service Brakes Adjustment.....................................................................................193
		Brake Pedal Adjustment........................................................................................193
		Parking Brake Adjustment......................................................................................194
		Troubleshooting...............................................................................................194
1900SRM802-1482626(04-2000)-EN........................................................................................200
	toc...............................................................................................................200
		Hydraulic System..............................................................................................200
		Safety Precautions Maintenance and Repair.....................................................................201
		General.......................................................................................................204
		Description...................................................................................................204
		Control Valve Repair..........................................................................................206
			Description...............................................................................................206
			Operation.................................................................................................206
				Lift..................................................................................................206
				Tilt and Auxiliary....................................................................................206
				Relief Valve..........................................................................................210
				Check Valves..........................................................................................210
					Description.......................................................................................210
					Clean and Inspect.................................................................................210
			Repairs...................................................................................................210
				Remove................................................................................................210
				Disassemble...........................................................................................211
				Relief Valve Repair...................................................................................211
				Clean and Inspect.....................................................................................212
				Assemble..............................................................................................212
				Install...............................................................................................212
			Checks....................................................................................................212
				Relief Valve Check....................................................................................212
			Adjust....................................................................................................213
				Relief Valve..........................................................................................213
				Control Levers, Linkage and Switches..................................................................213
		Hydraulic Pump Repair.........................................................................................215
			Description...............................................................................................215
			Repairs...................................................................................................215
				Remove................................................................................................215
				Seal, Replace.........................................................................................216
				Install...............................................................................................217
		Specifications................................................................................................219
			Relief Valves Pressures...................................................................................219
			Hydraulic System Capacity.................................................................................219
		Troubleshooting...............................................................................................219
			Hydraulic Pump............................................................................................219
			Control Valve.............................................................................................220
2100SRM103-910102(10-2003)-UK-EN......................................................................................226
	toc...............................................................................................................226
		Tilt Cylinders................................................................................................226
		Safety Precautions Maintenance and Repair.....................................................................227
		General.......................................................................................................230
		Description...................................................................................................230
		Tilt Cylinder Repair..........................................................................................230
			Remove....................................................................................................230
			Disassemble...............................................................................................230
			Clean.....................................................................................................230
			Assemble..................................................................................................231
				Tilt Cylinders With O-Ring or Single-Lip Seals........................................................231
				Tilt Cylinders for XM and XMS Models..................................................................232
				Tilt Cylinders for H700-800A and Early Model H700-920B................................................233
			Install...................................................................................................234
				Tilt Cylinders Using Chevron Packing..................................................................235
					Install...........................................................................................236
		Tilt Cylinder Leak Check......................................................................................238
		Tilt Cylinder Stroke and Mast Tilt Angle Adjustment...........................................................239
		Torque Specifications.........................................................................................240
			Piston Rod Nut............................................................................................240
			Retainer..................................................................................................241
		Troubleshooting...............................................................................................243
	tables............................................................................................................226
		Table 1. Movement Rates (Maximum) for Tilt Cylinders..........................................................239
2200SRM0143-910110(08-2004)-UK-EN.....................................................................................246
	toc...............................................................................................................246
		Instrument Panel Indicators and Senders.......................................................................246
		Safety Precautions Maintenance and Repair.....................................................................247
		General.......................................................................................................250
		Description...................................................................................................251
			Steering Column Gauges, Meters, and Indicators............................................................251
			LED Display Panel.........................................................................................251
				Battery Discharge Indicators..........................................................................251
				Brush Wear Indicators.................................................................................258
				Motor Temperature Indicators..........................................................................258
			LX Series Display Panel...................................................................................260
				Hourmeter Functions...................................................................................260
				Battery Indicator Function............................................................................261
				Status Code Function..................................................................................262
			ZX Series Display Panels..................................................................................262
				Display Panel.........................................................................................262
				Basic Display Panels..................................................................................262
				Performance Display...................................................................................265
				Brush Wear Indicators.................................................................................268
		Adjustments - General.........................................................................................269
		Replacement - General Information.............................................................................269
		Meter Replacement.............................................................................................270
		Sender Replacement............................................................................................271
			Fuel Level Sender.........................................................................................271
			Pressure and Temperature Sender...........................................................................271
		ITW Display Panel Replacement.................................................................................272
			Remove....................................................................................................272
		Column Mount Display Panel (EV-100/200ZX Motor Controllers) Repl..............................................273
			Remove....................................................................................................273
			Display Panel Assembly, Replace...........................................................................273
			Indicator LEDs............................................................................................274
			Battery Indicators........................................................................................274
			Digital Display (Performance Display Panel Only)..........................................................274
			Status Code or Performance Level Switches and Indicator LEDs (Pe..........................................274
			Basic Display Panel, Replace Parts........................................................................274
			Performance Display Panel, Replace Parts..................................................................276
		Dash Mount Display Panel (EV100/200ZX Motor Controllers) Replace..............................................277
			Remove and Replace........................................................................................277
		Specifications................................................................................................277
			Meter Specifications......................................................................................277
			Sender Specifications.....................................................................................278
		Troubleshooting...............................................................................................278
			Meter.....................................................................................................278
2200SRM0144-910111(05-1997)-EN........................................................................................282
	ELECTRICAL WARNING DEVICES........................................................................................282
		GENERAL.......................................................................................................282
		DESCRIPTION...................................................................................................282
			Operator Controlled Horns.................................................................................282
			System Warning Lights, Buzzers and Bells..................................................................282
			Reverse Warning Horns.....................................................................................283
			Warning Lights............................................................................................283
		REPLACEMENT...................................................................................................284
			General...................................................................................................284
			Replacing Horns or Bells..................................................................................284
			Replacing Horn Relay or Buzzer............................................................................284
			Replacing Warning Lights..................................................................................284
			Light Assemblies..........................................................................................285
			Replacing Flashing Units..................................................................................285
2200SRM0806-1482629(10-2001)-EN.......................................................................................286
	toc...............................................................................................................286
		Sevcon® SC2126 Motor Controller...............................................................................286
		Safety Precautions Maintenance and Repair.....................................................................287
		General.......................................................................................................290
			Lift Truck Control........................................................................................290
			Plugging..................................................................................................291
			Contactors................................................................................................291
			Circuit Protection........................................................................................292
				Current Limit.........................................................................................292
				Fuses.................................................................................................292
		Controller Operation..........................................................................................293
			General Operation.........................................................................................293
				Operating Frequency...................................................................................293
				Temperature Monitoring................................................................................293
				Safe Operating Area (SOA).............................................................................293
				Undervoltage and Overvoltage Protection...............................................................293
				Diagnostic LED........................................................................................294
				Fault Clearance.......................................................................................294
				Software Version and Revision Indication..............................................................294
				Setup Menu............................................................................................294
				Multi Languages.......................................................................................294
		Power Circuit Descriptions....................................................................................294
			Traction Operation........................................................................................295
				Start Up Sequence.....................................................................................295
				Static Return to Off (SRO)............................................................................295
				Seat Switch...........................................................................................295
				Acceleration Delay....................................................................................295
				Deceleration Delay....................................................................................295
				Creep.................................................................................................295
				Regenerative Braking..................................................................................295
				Plug Braking..........................................................................................296
				Brake Constant Factor.................................................................................296
				Antirollback..........................................................................................296
				Analog Inputs.........................................................................................296
				Traction Accelerator..................................................................................296
				Digital Switch Inputs.................................................................................296
				Contactors............................................................................................297
				Contactor Chopping....................................................................................297
				Fail-Safe.............................................................................................297
			Pump Operation............................................................................................297
				Pump Speeds and Priorities............................................................................298
				Additive Speeds.......................................................................................298
				Power Steer Speed.....................................................................................298
				Pump Inhibit Input....................................................................................298
				Pump Speed Compensation...............................................................................298
		Calibration and Adjustments...................................................................................299
			Traction Personalities (Controller Adjustments)...........................................................299
			Traction Status Information...............................................................................301
			Traction Test Information.................................................................................301
			BDI Adjustments...........................................................................................302
			Fault Log.................................................................................................302
			Setup Menu (Enables/Disables Features)....................................................................302
			Pump Personalities (Controller Adjustments)...............................................................302
			Pump Status Information...................................................................................303
			Pump Test Information.....................................................................................304
			Pump Setup Menu...........................................................................................304
			Traction and Pump Adjustment Descriptions.................................................................304
			Setup Menu Descriptions...................................................................................306
		Controller Connections........................................................................................307
			Power Connections.........................................................................................307
				Controller Connections................................................................................307
				Contactor Connections.................................................................................307
				Contactor Types.......................................................................................307
				Fuse Ratings..........................................................................................307
			Back Panel Connectors.....................................................................................307
				Connector A - 24 Pin..................................................................................308
				Connector B - 12 Pin..................................................................................308
				Connector C - 6 Pin...................................................................................309
			Controller Area Network (CAN) Overview....................................................................309
		Diagnostics...................................................................................................309
		Service and Fault Logs........................................................................................311
			Service Log...............................................................................................311
			Fault Log.................................................................................................311
		Technical Specifications......................................................................................312
			Environmental.............................................................................................312
			Mechanical................................................................................................312
			Electrical................................................................................................312
				Voltage Specifications:...............................................................................312
				Current Specifications:...............................................................................313
				Miscellaneous Controller Specifications:..............................................................313
		Contactor Repair..............................................................................................314
			General...................................................................................................316
			Remove Contactor Assembly.................................................................................316
			Contactor Contacts........................................................................................316
			Coil......................................................................................................316
		Control Switches..............................................................................................318
			Key Switch................................................................................................318
			Seat Switch...............................................................................................318
			Start Switch..............................................................................................318
		Brake Pedal Adjustment........................................................................................318
		Accelerator Pedal Adjustment..................................................................................319
	tables............................................................................................................286
		Table 1. Over- and Undervoltage Protection....................................................................293
2200SRM1014-1515047(11-2001)-EN.......................................................................................322
	toc...............................................................................................................322
		Sevcon Traction and Pump Controllers..........................................................................322
		Safety Precautions Maintenance and Repair.....................................................................323
		Sevcon PCpak..................................................................................................328
			Introduction..............................................................................................328
			System Requirements.......................................................................................328
		Traction Controller Safety....................................................................................328
		Traction Controller Introduction..............................................................................329
		Traction Controller Installation..............................................................................329
			Mounting..................................................................................................329
		Traction Controller Calibration...............................................................................331
			Adjustments...............................................................................................331
			Status and Test Information...............................................................................332
		Traction Controller Configuration.............................................................................333
			System Configuration......................................................................................333
			System Voltage............................................................................................333
			System I/O Configuration..................................................................................333
			System/Motor Setup........................................................................................335
			Armature Field Map........................................................................................335
			Armature and Field Current Limit..........................................................................336
			Contactor Chopping........................................................................................337
			Accelerator Full/Zero Setting.............................................................................337
			Performance...............................................................................................337
			Acceleration Delay........................................................................................337
			Deceleration Delay........................................................................................337
			Control Mode..............................................................................................338
			Plugging..................................................................................................338
			Types of Braking..........................................................................................338
			Braking Levels............................................................................................338
			Footbraking...............................................................................................338
			Footbrake Pot.............................................................................................339
			Footbrake Priority........................................................................................340
			Creep Speed...............................................................................................340
			Maximum Speed.............................................................................................340
		Traction Controller Commissioning.............................................................................340
			Checklist.................................................................................................340
		Traction Controller Features..................................................................................342
			Accelerator Characteristics...............................................................................342
			Features..................................................................................................343
			Standard Controller Features..............................................................................343
			Power Steer...............................................................................................343
			High Speed Switch and Anti-Tie Down.......................................................................344
			Seat Switch...............................................................................................345
			Traction Drive Hours Meter................................................................................345
			Personality Checksum......................................................................................345
			Reverse Buzzer............................................................................................345
		Traction Controller Safety Features...........................................................................345
			Start Up Sequence.........................................................................................345
			SRO (Static Return to Off)................................................................................345
			Belly Switch (not used)...................................................................................346
			Anti-Rollback.............................................................................................346
			Anti-Rolloff..............................................................................................346
			Fail-Safe.................................................................................................346
		Traction Controller Protection................................................................................346
			Controller Protection Features............................................................................346
			Temperature Monitoring....................................................................................346
			Maximum Temperature Logging...............................................................................347
			Timed Current Cutback.....................................................................................347
			Safe Operating Area (SOA).................................................................................348
			Under-Voltage and Over-Voltage Protection.................................................................349
		Traction Controller Diagnostics...............................................................................350
			Fault Codes...............................................................................................350
			Fault Code Clearance......................................................................................351
			Software Version and Serial Number Indication.............................................................351
		Traction Controller Specifications............................................................................352
			Power Configurations......................................................................................352
			EMC Standards.............................................................................................352
			Socket B Protection.......................................................................................352
			Contactor Drive Ratings...................................................................................352
			Analogue Input Impedance..................................................................................352
			Digital Input Impedance...................................................................................352
			EMC Guidelines............................................................................................352
			Power Cables..............................................................................................353
			Signal Cables.............................................................................................353
			Controller................................................................................................353
		Pump Controller Safety........................................................................................353
		Pump Controller Introduction..................................................................................353
		Pump Controller Installation..................................................................................354
			Mounting..................................................................................................354
			MillipaK Pump Power Wiring................................................................................354
		Pump Controller Calibration...................................................................................355
			Adjustments...............................................................................................355
			Status and Test Information...............................................................................356
		Pump Controller Configuration.................................................................................357
			System Configuration......................................................................................357
			System Voltage............................................................................................357
			System I/O Configuration..................................................................................357
			Current Limit.............................................................................................358
			Accelerator Full/Zero Setting.............................................................................358
			Performance...............................................................................................359
			Lift and Power Steer Ramps................................................................................359
			Creep Speed...............................................................................................359
			Maximum Speed.............................................................................................359
		Pump Controller Commissioning.................................................................................360
			Under-Voltage Protection..................................................................................360
			Commissioning Checklist...................................................................................360
			Personalities Record......................................................................................361
		Pump Controller Features......................................................................................362
			Features..................................................................................................362
			Standard Controller Features..............................................................................362
			Lift Switch Inputs - Priority.............................................................................362
			Lift Switch Inputs - Additive.............................................................................363
			Compensation..............................................................................................363
			Power Steer Input.........................................................................................363
			Lift Inhibit Input........................................................................................364
			Cooling Fan...............................................................................................364
			Pump Hours Meter..........................................................................................364
			Personality Checksum......................................................................................364
		Pump Controller Safety Features...............................................................................364
			Fail-safe.................................................................................................364
		Pump Controller Protection....................................................................................364
			Controller Protection Features............................................................................364
			Temperature Monitoring....................................................................................364
			Maximum Temperature Logging...............................................................................365
			Timed Current Cutback.....................................................................................365
			Safe Operating Area (SOA).................................................................................366
		Pump Controller Diagnostics...................................................................................366
			Diagnostics...............................................................................................366
			Fault Clearance...........................................................................................367
			Using Status and Test Menus...............................................................................367
			Software Version and Serial Number Indication.............................................................368
		Pump Controller Specifications................................................................................369
			Power Configurations......................................................................................369
			EMC Standards.............................................................................................369
			Socket B Protection.......................................................................................369
			Contactor Drive Ratings...................................................................................369
			Analogue Input Impedance..................................................................................369
			Digital Input Impedance...................................................................................369
		Ordering Information..........................................................................................370
			EMC Guidelines............................................................................................370
			Power Cables..............................................................................................370
			Signal Cables.............................................................................................370
			Controller................................................................................................370
	tables............................................................................................................322
		Table 1. Adjustment Menus.....................................................................................331
		Table 2. Status and Test Information Menus....................................................................332
		Table 3. Description of each Digital I/O Configuration........................................................333
		Table 4. Digital Functions....................................................................................334
		Table 5. Pin Allocations......................................................................................335
		Table 6. Analogue Functions...................................................................................335
		Table 7. Personality Record...................................................................................340
		Table 8. Internal Power Steer Triggers........................................................................343
		Table 9. Timed Current Limit Cutback Levels...................................................................347
		Table 10. Under- and Over-Voltage Cutback Levels..............................................................349
		Table 11. Flash Fault Descriptions............................................................................350
		Table 12. Fault Codes and Descriptions........................................................................350
		Table 13. Software Version Format.............................................................................351
		Table 14. Serial Number Format................................................................................352
		Table 15. Power Configurations................................................................................352
		Table 16. Analogue Function...................................................................................358
		Table 17. Personality Record..................................................................................361
2240SRM001-899648(03-2003)-EN.........................................................................................374
	toc...............................................................................................................374
		Industrial Battery............................................................................................374
		Safety Precautions Maintenance and Repair.....................................................................375
		General.......................................................................................................378
		Lead-Acid Batteries...........................................................................................378
		Specific Gravity..............................................................................................379
		Chemical Reaction in a Cell...................................................................................379
		Electrical Terms..............................................................................................380
		Battery Selection.............................................................................................381
		Battery Voltage...............................................................................................382
		Battery as a Counterweight....................................................................................382
		Battery Ratings...............................................................................................382
			Kilowatt-Hours............................................................................................382
		Battery Maintenance...........................................................................................383
			Safety Procedures.........................................................................................383
			Maintenance Records.......................................................................................383
			New Battery...............................................................................................383
			Cleaning Battery..........................................................................................384
			Adding Water to Battery...................................................................................385
			Hydrometer................................................................................................386
			Battery Temperature.......................................................................................386
			Charging Battery..........................................................................................387
				Types of Battery Charges..............................................................................388
				Methods of Charging...................................................................................389
				Troubleshooting Charger...............................................................................390
				Knowing When Battery Is Fully Charged.................................................................390
			Where to Charge Batteries.................................................................................390
				Equipment Needed......................................................................................390
			Battery Connectors........................................................................................391
			Battery Care..............................................................................................391
	tables............................................................................................................374
		Table 1. Battery Capacity Terms...............................................................................382
2260SRM138-910114(10-2000)-EN.........................................................................................396
	INTRODUCTION......................................................................................................396
		GENERAL.......................................................................................................396
		INDICATORS WITH METER MOVEMENTS...............................................................................397
		BATTERY INDICATORS WITH LCD OR LED DISPLAYS...................................................................398
			Liquid Crystal Displays...................................................................................398
			Light Emitting Diode Displays.............................................................................399
	CHECKS AND ADJUSTMENTS............................................................................................402
		BATTERY INDICATORS WITHOUT LIFT INTERRUPT, EARYLY MODELS......................................................402
		BATTERY INDICATORS WITH LIFT INTERRUPT, EARLY MODELS..........................................................403
			Reset Potentiometer.......................................................................................403
			Specific Gravity Alarm....................................................................................403
		BATTERY INDICATORS WITHOUT LIFT INTERRUPT, LATER MODELS.......................................................403
		BATTERY INDICATORS WITH LIFT INTERRUPT, LATER MODELS..........................................................403
			Reset Potentiometer.......................................................................................404
			Discharge Potentiometer...................................................................................404
		LED DISPLAY WITH LIFT INTERRUPT...............................................................................404
		CHECKING CURTIS 933-1 METER...................................................................................404
			Reset Check ..............................................................................................405
			Discharge Check...........................................................................................405
			Lockout Check.............................................................................................406
			Hour Glass Icon...........................................................................................406
		ADJUSTMENT OF CURTIS 933-1 METER..............................................................................407
		CHECKING CURTIS 1215 BATTERY INDICATOR........................................................................407
		ADJUSTING CURTIS 1215 BATTERY INDICATOR.......................................................................408
			Voltage Selection.........................................................................................409
	REPAIRS...........................................................................................................410
	BATTERY INDICATORS................................................................................................410
		Replacement...................................................................................................410
	CONTROLLER FOR THE BATTERY INDICATOR..............................................................................410
		Replacement...................................................................................................410
	DISPLAY PANEL COMPONENTS..........................................................................................410
4000SRM222-899237(04-2000)-EN.........................................................................................411
	INTRODUCTION......................................................................................................411
		GENERAL.......................................................................................................411
		MAST WELDMENTS................................................................................................411
		CARRIAGE......................................................................................................411
		MAST MOUNTS...................................................................................................412
	VISTA® TWO-STAGE MAST.............................................................................................413
		DESCRIPTION AND OPERATION.....................................................................................413
	VISTA® FREE-LIFT MAST.............................................................................................415
		DESCRIPTION...................................................................................................415
		OPERATION.....................................................................................................415
	VISTA® THREE-STAGE MAST...........................................................................................417
		DESCRIPTION...................................................................................................417
		OPERATION.....................................................................................................417
	VISTA® FOUR-STAGE MAST............................................................................................418
		DESCRIPTION...................................................................................................418
		OPERATION.....................................................................................................419
4000SRM374-897209(03-1993)-EN.........................................................................................421
	SAFETY PROCEDURES WHEN WORKING NEAR THE MAST......................................................................421
	INTRODUCTION......................................................................................................422
		GENERAL.......................................................................................................422
		FORKS.........................................................................................................422
		CARRIAGE......................................................................................................423
			Removal...................................................................................................423
			Installation..............................................................................................423
	MAST..............................................................................................................424
		REMOVAL FROM THE LIFT TRUCK...................................................................................424
		DISASSEMBLY...................................................................................................425
			Two-Stage And Free-Lift Masts.............................................................................425
			Three-Stage Mast..........................................................................................426
		CLEANING AND INSPECTION.......................................................................................428
		ASSEMBLY......................................................................................................429
			Two-Stage And Free-Lift Mast..............................................................................429
			Two-Stage Mast............................................................................................430
			Free-Lift Mast............................................................................................430
			Three-Stage Mast..........................................................................................430
		INSTALLATION..................................................................................................431
	LIFT CYLINDERS....................................................................................................432
		DESCRIPTION...................................................................................................432
		LOWERING CONTROL VALVE........................................................................................434
		REMOVAL OF THE LIFT CYLINDERS WITHOUT REMOVING THE MAST.......................................................435
		DISASSEMBLY...................................................................................................436
			Main Lift Cylinders.......................................................................................436
			Free-lift Cylinder........................................................................................436
		ASSEMBLY......................................................................................................436
			Main Lift Cylinders.......................................................................................436
			Free-Lift Cylinders.......................................................................................436
		INSTALLATION OF THE LIFT CYLINDERS INTO THE MASTS.............................................................437
			Main Lift Cylinders.......................................................................................437
			Free-Lift Cylinder........................................................................................437
		TILT CYLINDER.................................................................................................437
		DESCRIPTION...................................................................................................437
		REMOVAL.......................................................................................................438
		DISASSEMBLY...................................................................................................438
		CLEANING......................................................................................................438
		ASSEMBLY......................................................................................................438
		INSTALLATION..................................................................................................438
		SIDE-SHIFT CARRIAGE...........................................................................................439
			Removal...................................................................................................439
			Removal...................................................................................................439
			Repairs...................................................................................................439
			Installation..............................................................................................440
	CHECKS AND ADJUSTMENTS............................................................................................442
		CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM...................................................................442
			Check The Lift Cylinder For Leaks.........................................................................442
			Check The Tilt Cylinder For Leaks.........................................................................443
		ADJUSTMENT OF THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE............................................443
		LIFT CHAIN ADJUSTMENTS........................................................................................443
		MAST ADJUSTMENTS..............................................................................................444
		CARRIAGE ADJUSTMENT...........................................................................................446
		SIDE-SHIFT CYLINDER ADJUSTMENT................................................................................446
8000SRM231-910442(03-2004)-EN.........................................................................................448
	toc...............................................................................................................448
		Metric and Inch (SAE) Fasteners...............................................................................448
		Safety Precautions Maintenance and Repair.....................................................................449
		General.......................................................................................................452
			Threaded Fasteners........................................................................................452
			Nomenclature, Threads.....................................................................................452
			Strength Identification...................................................................................453
			Cotter (Split) Pins.......................................................................................453
			Fastener Torque Tables....................................................................................458
			Conversion Table..........................................................................................460
	tables............................................................................................................448
		Table 1. Bolts and Screws.....................................................................................454
		Table 2. Studs and Nuts.......................................................................................455
		Table 3. Torque Nuts..........................................................................................456
		Table 4. Torque Nuts With Nylon Insert........................................................................457
		Table 5. Torque Values for Metric Fasteners*..................................................................458
		Table 6. Torque Values for Inch Fasteners*....................................................................459
		Table 7. Conversion Table for Metric and English Units........................................................460
		Table 8. Cotter Pin Dimensional Data..........................................................................461
		Table 9. Cotter Pin Dimensional Data..........................................................................462
		Table 10. Cotter Pin Dimensional Data.........................................................................463
		Table 11. Cotter Pin Dimensional Data.........................................................................465
8000SRM798-1482632(03-2000)-EN........................................................................................468
	toc...............................................................................................................468
		Periodic Maintenance..........................................................................................468
		Safety Precautions Maintenance and Repair.....................................................................469
		General.......................................................................................................472
			How to Move Disabled Lift Truck...........................................................................472
				How to Tow Lift Truck.................................................................................472
			How to Put Lift Truck on Blocks...........................................................................473
				How to Raise Load Wheels..............................................................................473
				How to Raise Steer Wheels.............................................................................474
		Safety Procedures When Working Near Mast......................................................................474
		Maintenance Schedule..........................................................................................476
		Maintenance Procedures Every 8 Hours or Daily.................................................................478
			Checks Before Operation...................................................................................478
				Hydraulic System......................................................................................478
				Battery...............................................................................................479
				Battery Restraint System..............................................................................479
				Operator Restraint System.............................................................................480
				Mast, Forks, and Lift Chains..........................................................................480
				Lift Chain Adjustments................................................................................482
				Tires and Wheels......................................................................................482
			Check Operation...........................................................................................483
				Gauges and Horn.......................................................................................483
				Control Levers and Pedals.............................................................................483
				Lift System Operation.................................................................................483
				Service Brakes........................................................................................484
				Parking Brake.........................................................................................484
				Steering System.......................................................................................484
		Maintenance Procedures Every 500 Hours or 2 Months............................................................484
			Hydraulic Tank Breather...................................................................................484
			Wheel Nut Torques.........................................................................................484
			Master Drive Unit (MDU)...................................................................................484
			Mast......................................................................................................485
			Lift Chains...............................................................................................485
			Forks.....................................................................................................486
			Safety Labels.............................................................................................486
			Brake Fluid...............................................................................................486
			Other Lubrication.........................................................................................486
			Electrical Inspection.....................................................................................487
				Contactors............................................................................................487
				Motor Brushes.........................................................................................487
		Maintenance Procedures Every 2000 Hours or Yearly.............................................................488
			Hydraulic System..........................................................................................488
				Change Hydraulic Oil Filter...........................................................................488
				Change Hydraulic Oil..................................................................................488
			Brake Shoes...............................................................................................488
			Steering System...........................................................................................488
			Master Drive Unit.........................................................................................488
			Adjust Service Brakes.....................................................................................489
			Adjust Parking Brake......................................................................................489
		Lift and Tilt System Leak Check...............................................................................490
			Lift System...............................................................................................490
			Tilt System...............................................................................................491
		Battery Maintenance...........................................................................................491
			How to Charge Battery.....................................................................................491
			How to Change Battery.....................................................................................492
			Battery Size Specifications...............................................................................493
		Wheel and Tire Maintenance....................................................................................494
			General...................................................................................................494
			How to Change Tires.......................................................................................494
			Solid Rubber Tires on Pneumatic Wheels....................................................................494
				Remove Wheels From Lift Truck.........................................................................494
				Remove Solid Rubber Tire From Pneumatic Wheel.........................................................495
				Install Solid Rubber Tire on Pneumatic Wheel..........................................................496
				Wheels, Install.......................................................................................497
	tables............................................................................................................468
		Table 1. Maintenance Schedule.................................................................................477
		Table 2. Battery Size Specifications - Type: Lead-Acid Battery................................................493
8000SRM804-1482635(04-2000)-EN........................................................................................500
	toc...............................................................................................................500
		Capacities and Specifications.................................................................................500
		Safety Precautions Maintenance and Repair.....................................................................501
		Wheels and Tires..............................................................................................504
		Hydraulic System..............................................................................................504
		Motors (24 Volt)..............................................................................................504
		Mast Creep Speeds.............................................................................................504
		Mast Speeds...................................................................................................505
		Battery Size Specifications...................................................................................506
		Torque Specifications.........................................................................................506
			Frame.....................................................................................................506
			Master Drive Unit (MDU) (ZF Gotha)........................................................................506
			Master Drive Unit (MDU) (Kordel)..........................................................................506
			Steering System...........................................................................................506
			Brake System..............................................................................................507
			Hydraulic System..........................................................................................507
			Mast......................................................................................................507
			Wheels....................................................................................................507
		Sevcon SC2126 Motor Controller Adjustments....................................................................507
8000SRM805-1482638(10-2001)-EN........................................................................................510
	Schematics........................................................................................................512
		Figure 1. Lift Truck Control Wire Diagram Last Used 10/01.....................................................512
		Figure 2. Electrical Connection Diagram.......................................................................517
		Figure 3. Hydraulic Schematic.................................................................................519
		Figure 4. Control Unit Connector Layout.......................................................................520
		Figure 5. Control Wire Diagrams First Used 10/01..............................................................521
		Figure 6. Control Unit Connector Diagrams First Used 10/01....................................................523

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