Hyster E098 (E70Z, E80Z, E100Z/ZS, E120Z) Forklift Service Manual
759 pages · Publication 1596596
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- Models
- E098 (E70Z, E80Z, E100Z/ZS, E120Z)
- Manual type
- Service Manual
- Pages
- 759
- Publication
- 1596596
- Condition
- Brand new
What's inside
From the manual's own table of contents: 145 sections, 453 entries. See sample pages (PDF, 272 KB)
Steering Axle
Safety Precautions Maintenance and Repair
General
Description
Steering Axle Assembly Repair4 topics
- Remove
- Install
- Remove
- Install
Wheels and Hubs Repair (All Units)4 topics
- Remove and Disassemble
- Clean
- Inspect
- Assemble and Install
Spindles and Bearings Repair (All Units)1 topic
- Remove
Tie Rods Repair (All Units)1 topic
- Install
Steering Cylinder Repair1 topic
- Clean and Inspect
Troubleshooting
Brake System
Description and Operation5 topics
- Brake Booster and Master Cylinder
- Master Cylinder
- Service Brake Assembly
- Parking Brake
- Seat Brake
Brake Shoe Assemblies Repair
Master Cylinder Repair9 topics
- Master Cylinder For Lift Truck Models S3.50-5.50XL (S70-120XL) (
- Remove
- Disassemble
- Assemble
- Install
- Master Cylinder For Lift Truck Models E3.50-5.50XL (E70-120XL, E
- Remove and Disassemble
- Clean and Inspect
- Assemble and Install
Brake Booster Repair2 topics
- Disassemble
- Assemble
Brake System Air Removal
Brake Pedal Adjustment
Brake Shoes Adjustment
Parking Brake Adjustment2 topics
- Parking Brake Adjustment, Lift Truck Models S3.50-5.50XL (S70-12
- Parking Brake Lever and Switch Adjustment E3.50-5.50XL (E70-120X
Seat Brake Assembly4 topics
- Adjustments
- Solenoid Adjustment
- Traction cutoff Switch Adjustment
- Cable Adjustment
Brake Booster Relief Valve Check
Drive Axle, Speed Reducer, and Differential
Drive Axle, Speed Reducer, and Differential Repair11 topics
- General
- Traction Motor, Speed Reducer, and Differential
- Speed Reducer
- Differential
- Speed Reducer
- Differential
- Drive Axle Housing
- Remove
- Clean
- Inspect
- Assemble
Table 1. Pinion Assembly Shims Adjustment
Show all 145 sections
Table 2. Ring and Pinion Tooth Contact Adjustment
Hydraulic System
Operation3 topics
- Hydraulic Gear Pump
- Rotator Actuator Valve
- Steering Pump
Hydraulic Tank Repair5 topics
- Small Leaks, Repair
- Large Leaks, Repair
- Steam Method
- Chemical Solution Method
- Additional Methods for Tank Repair
Filter Replacement8 topics
- Remove
- Install
- Remove
- Install
- Remove
- Install
- Remove
- Install
Hydraulic Pump Repair2 topics
- Pump Seal Replace and Pump Assemble
- Assemble Pump on Motor
Main Control Valve Repair
Steering Pump Repair1 topic
- Pump, Assemble and Install
Rotary Actuator Valve Repair1 topic
- Disassemble, Clean, and Inspect
Steering Control Unit Replacement
Main Control Valve Check and Adjust
Steering Relief Valve Check and Adjust
Specifications6 topics
- Relief Valve Pressures*
- Hydraulic Tank Capacity (dipstick full mark)
- Hydraulic Pump Capacities - All Models Except E3.50-5.50XL, E4.5
- Hydraulic Pump Capacities - Models E3.50-5.50XL, E4.50XLS (E70-1
- Steering
- Steering Housing and Steering Control Unit
Manual hydraulic Control Valve10 topics
- Lift Section
- Tilt Section
- Tilt Backward
- Tilt Forward
- Relief Valve
- Solenoid Valve for Auxiliary Function
- Remove and Disassemble - Control Valve Without OPS Solenoid
- Remove and Disassemble - Control Valve With OPS Solenoid
- Assemble - Control Valve Without OPS
- Assemble - Control Valve With OPS
Solenoid Valve for Auxiliary Function Repair1 topic
- Troubleshooting
Pressure Relief Valve Check and Adjustment2 topics
- Primary Relief Valve
- Secondary Relief Valve
Control Lever Arrangement and Adjustment
Tilt Cylinders
Tilt Cylinder Repair5 topics
- Tilt Cylinders With O-Ring or Single-Lip Seals
- Tilt Cylinders for XM and XMS Models
- Tilt Cylinders for XL, XLS, and XL 3 Models
- Tilt Cylinders for H700-800A and Early Model H700-920B
- Tilt Cylinders Using Chevron Packing
Tilt Cylinder Leak Check
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment
Torque Specifications2 topics
- Piston Rod Nut
- Retainer
Table 1. Movement Rates (Maximum) for Tilt Cylinders
Steering Housing and Control Unit
Steering Wheel and Column Assembly Repair5 topics
- Assembly Components, Remove
- Steering Control Unit, Disassemble
- Steering Control Unit, Clean
- Steering Control Unit, Assemble
- Assembly Components, Install
System Air Removal
Masts4 topics
- Carriages
- Two-Stage Mast With Limited Free-Lift
- Two-Stage Mast With Full Free-Lift
- Three-Stage Mast With Full Free-Lift
Safety Procedures When Working Near Mast
Fork Replacement
Carriage Repair
Sideshift Carriage Repair
Two-Stage Mast With Limited Free-Lift Repair
Two-Stage Mast With Full Free-Lift Repair
Three-Stage Mast With Full Free-Lift Repair
Mast Operation Check
Lift and Tilt System Leak Check2 topics
- Lift System
- Tilt System
Tilt Cylinder Stroke and Backward Tilt Angle Adjustment
Lift Chain Adjustments
Mast Adjustments
Carriage Adjustment
Table 1. Tilt Cylinder Leak Check Specifications, S3.50-5.50XM (
Table 2. Hook-Type Carriage Chain Adjustment
Table 3. Pin-Type Carriage Chain Adjustment
Lift Cylinders1 topic
- Lowering Control Valve (Velocity Fuse)
Lift Cylinder Repair
Lift System Leak Check
Steering System for AC Electric Lift Trucks1 topic
- General
Power Steering Motor and Pump3 topics
- Description
- Power Steering Pump, Repair
- Seal, Replace
Steering System Air Removal
Steering Pressure Check
Steering Motor Circuits Check
Electrical System (Trucks With AC Controllers)2 topics
- Features of the Display Panels
- Other Control Components
Display Panel and Key Switch Replacement2 topics
- Display Panel, Replace
- Key Switch, Replace
Controller Replacement2 topics
- Traction and Pump Motor Controller Replacement
- Master Controller, Replace
Control Components Replacement26 topics
- Start Switch, Replace
- Brake Light Switch, Replace
- Seat Switch, Replace
- Parking Brake Switch, Replace
- MONOTROL Pedal Direction Switches, Replace
- Steering Column Direction Control Switches, Replace
- Remove
- Install
- Brake Fluid Switch, Replace
- Brush Wear and Over Temperature Sensors (DC Pump Motor Only)
- Rocker Switches for Lights, Replace
- Accelerator Position Sensor, Replace
- On-Demand Steering Sensor, Replace
- Lights, Converter, Relay, and Reverse Alarm
- Brake, Tail, and Reverse Light Assembly, Replace
- Strobe Light Assembly, Replace
- Wire Harness Repair
- Front, Rear Driving Light or Spot Light Assemblies, Replace
- Converter, Replace
- Reverse Relay, Replace
- Backup Alarm, Replace
- Horn and Horn Button, Replace
- Horn Replacement for Lift Trucks E3.50-5.50XL, E4.50XLS (E70-120
- Horn Switch and Cover, Replace
- Hydraulic Pump Switches
- Fan Power Supply, Replace
Control and Power Fuse Check1 topic
- Fuse Locations
Brake Light Switch Adjustment
Seat Switch Check
Seat Brake Adjustment
Parking Brake Switch Adjustment
Direction Switches Check2 topics
- MONOTROL Pedal
- Steering Column
MONOTROL Pedal or Accelerator Pedal Adjustment
Accelerator Position Sensor Adjustment and Start Switch Adjustme2 topics
- Acceleration Position Sensor, Adjust
- Start Switch, Adjust
Table 1. Wire Splice Size
AC Motor Controllers/Display Panel5 topics
- AC Motors
- Motor Controllers
- Master Controller
- Dash Display
- Controller Area Network Bus (CANbus)
Master Controller Checks and Adjustments
Function Settings1 topic
- Function Numbers
Function Descriptions20 topics
- Function Number 1 BATTERY VOLTAGE
- Function Number 2 EXTENDED SHIFT
- Function Number 3 ACCELERATION 1
- Function Number 4 ACCELERATION 2
- Function Number 5 TOP SPEED LIMIT
- Function Number 6 REGEN BRAKING
- Function Number 7 AUTO DECELERATION
- Function Number 8 BDI ADJUSTMENT
- Function Number 9 LIFT INTERRUPT
- Function Number 10 POWER STEERING TIME DELAY
- Function Number 11 SERVICE REMINDER
- Function Number 12 CUSTOM
- Function Number 13 PUMP SPEED 1
- Function Number 14 PUMP SPEED 2
- Function Number 15 PUMP SPEED 3
- Function Number 16 PUMP ACCELERATION
- Controller Status Light Emitting Diodes (LEDs)
- Master Controller
- AC Motor Controllers
- Status Codes
AC Motor Controllers Status Code Charts6 topics
- Troubleshooting When Dash and/or Lift Truck is not Operational
- Typical Symptoms
- Truck Runs but Dash Display is not Operational, or Only Displays
- Truck Does Not Run and Dash is Not Operational or Only Displays
- Hydraulics Operate Normally, Traction Does Not Operate Correctly
- Traction Operates Normally, Hydraulics do Not Operate Correctly
AC Transistor Motor Controller Replacement8 topics
- General Maintenance Instructions
- Special Precautions
- Fuses
- Fan Test
- Contactors
- Repair
- Thermal Sensors
- Motor Controller, Replace
Display Panel2 topics
- Premium Display Panel
- Standard Display Panel
Display Functions and Features9 topics
- Key-On Initialization
- Standard Display
- Premium Display
- Lift Truck Inspection Function
- Access to Service Functions
- Service Functions
- Performance Modes
- Battery Discharge Indicator (BDI)
- Hourmeter
Dash Display Service Menu Navigation2 topics
- Moving Through Menu Selections
- Editing and Adding Information
Table 5. List of Status Codes
Table 6. 42-Pin Connections/Descriptions for Master Controller
Table 7. Pin Connections/Descriptions for 72/80 (Gen IV) Volt Mo
Table 8. Pin Connections/Descriptions for 36/48 and 72v/80v (Gen
Troubleshooting and Adjustments Using the AC Controls Program (E6 topics
- Computer Requirements
- Software, Install
- Language Selection
- Demo Mode
- Connect PC to Lift Truck
- Starting AC Controls Program
Lift Truck Control Setup6 topics
- Change Lift Truck Serial Number or Hourmeter
- Setting Factory Default Values or Changing Lift Truck Parameters
- Create New Custom Lift Truck Configuration
- Lift Truck Configuration Properties
- Import New Lift Truck Configuration From Disk
- Delete Custom Lift Truck Configuration or Password File
Dash Display3 topics
- Custom Display Languages
- Download Display Language
- Clear Operator Log
Password Functions7 topics
- Enable/Disable Password and Lift Truck Inspection Functions
- Truck Inspection Checklist
- Password
- Password Properties
- Create New Password File
- Download Passwords
- Upload Passwords
Reports Menu8 topics
- Devices Report
- Custom Report
- Password Report
- Operator Report
- Current Settings Report
- Status Code Report
- Status Codes Log
- Diagnostics
Help Menu2 topics
- Technical Support
- About Electric Truck AC Controls Program
AC Motor Repair
Frame
Overhead Guard Replacement
Battery and Operator Restraint, Hood and Seat Brake Repair5 topics
- Battery Restraint and Hood Repair
- Operator Restraint System and Seat Assembly
- Automatic Locking Retractor (ALR)
- Emergency Locking Retractor (ELR)
- Seat Brake Repair
Counterweight Replacement
Traction Motor Repair3 topics
- Steam Method
- Chemical Solution Method
- Additional Preparations For Repair
Safety Label Replacement
Battery Specifications
Table 1. Torque Values
Table 2. Weight of Counterweights
Table 3. Battery Specifications*
Periodic Maintenance6 topics
- How to Move Disabled Lift Truck
- How to Tow Lift Truck
- How to Put Lift Trucks on Blocks
- How to Raise Drive Tires
- How to Raise Steering Tires
- How to Clean a Lift Truck
Maintenance Schedule
Maintenance Procedures Every 8 Hours or Daily20 topics
- How to Make Checks With Key Switch OFF
- Tires and Wheels
- Forks
- Inspection of Mast, Mast Pivots, Header Hoses and Lift Chains
- Safety Labels
- Steering Column Latch
- Operator Restraint System
- Battery Restraint System
- Battery
- Hydraulic System
- How to Make Checks With Key Switch ON
- Horn, Lights, and Alarm
- Steering System
- Service Brakes
- Parking Brake
- Seat Brake
- Control Levers and Pedals
- Direction and Speed Control Pedals
- Lift System Operation
- Oil Leaks
First Service After First 100 Hours of Operation1 topic
- Change Hydraulic Oil and Filter
Maintenance Procedures Every 500 Hours or 3 Months6 topics
- Wheel Nuts
- Header Hose Checks
- Mast Lubrication
- Integral Sideshift Carriage
- Brake Fluid
- Other Lubrication
Maintenance Procedures Every 1000 Hours or 6 Months11 topics
- Differential and Speed Reducer
- Lift Chains
- Wear Check
- Lubrication
- Forks
- Brake Linkage Shafts
- Steering Spindles and Tie Rod Ends
- Seat Rails
- Seat Plate Hinges
- Electrical Inspection
- Contactors
Maintenance Procedures Every 2000 Hours or Yearly8 topics
- Hydraulic Tank Breather, Lift Truck Models E3.50-5.50XL (E70-120
- Change Hydraulic Oil and Hydraulic Oil Filter, Lift Truck Models
- Hydraulic Tank Breather, Lift Truck Models E3.50-5.50XL (E70-120
- Change Hydraulic Oil and Hydraulic Oil Filter, Lift Truck Models
- Service Brakes
- Wheel Bearings
- Steer Wheels, Lubrication
- Drive Wheels, Lubrication
Battery Maintenance4 topics
- How to Charge Battery
- How to Change Battery
- Check Lift Cylinders for Leaks
- Check Tilt Cylinders for Leaks
Welding Repairs
Overhead Guard Changes
Wheels and Tires5 topics
- Remove Wheels From Lift Truck
- Remove Tire From Wheel and Install Tire on Wheel
- Remove
- Install
- Install Wheels
Table 1. Maintenance Schedule
Table 2. Battery Specifications*
Table 3. Hook-Type Carriage Chain Adjustment
Capacities and Specifications
Lift Truck Lifting Capacity
Counterweight Weights
Tire Sizes
Capacities
Steering System2 topics
- Specifications
- Turning Radius
Mast Speeds
Maximum Carriage and Tilt Creep Rates
Traction Motor Speed
Battery Current at Hoist Relief9 topics
- Brake System
- Differential
- Drive Axle
- Frame
- Mast
- Main Control Valve
- Steering System
- Tilt Cylinders
- Electrical System
Table 1. Manual Control Valve
Table 2. E-Hydraulic Control Valve
Diagrams
Inside this manual
Real pages from this service manual (759 pages). Open the sample pages (PDF, 272 KB)
- Troubleshooting, page 484: AC Motor Controllers Status Code Charts
- Specifications, page 638: Counterweight Replacement
- Diagram, page 726: Diagrams, Schematics, or Arrangements
This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 759 pages
Quantity one is the manual described above.
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Other editions and similar models
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