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Hyster E70-120XL (C098) Forklift Service Manual

1,102 pages · Publication 897319

$119.81
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Models
E70-120XL (C098)
Manual type
Service Manual
Pages
1,102
Publication
897319
Condition
Brand new
Hyster E70-120XL (C098) Forklift Service Manual, publication 897319

What's inside

From the manual's own table of contents: 163 sections, 551 entries. See sample pages (PDF, 133 KB)

Frame
Safety Precautions Maintenance and Repair
General
Description
Overhead Guard Repair2 topics
  • Remove
  • Install
Battery Restraint and Seat Assembly Repair2 topics
  • Seat Brake Assembly E/J1.25-3.00XL (E/J25-60XL), Adjust
  • Seat Brake Assembly E3.50-5.50XL (E70-120XL), Adjust
Counterweight Repair
Traction Motor Repair
Hydraulic Tank Repair7 topics
  • Inspect
  • Small Leaks, Repair
  • Large Leaks, Repair
  • Clean
    • Steam Method
    • Chemical Solution Method
  • Additional Preparations For Repair
Painting Instructions
Safety Label Replacement
Table 1. Battery Specifications (Battery without Cover)
Table 2. Battery Specifications (Battery with Flat Cover)
Table 3. Battery Specifications (Battery with Dome Cover)
Table 4. Battery Specifications*
Table 5. Seat Brake Adjustment
Table 6. Counterweights
DC Motor Maintenance
Brush and Commutator Inspection4 topics
  • Hydraulic Pump Motor and Traction Motor
  • Steering Pump Motor
  • Normal Commutator Surface
  • Commutator Problems
Brush Replacement
Stoning the Commutator
Motors Repair6 topics
  • Disassemble
    • Traction Motor and Hydraulic Pump Motor
    • Steering Pump Motor
  • Assemble
    • Traction Motor and Hydraulic Pump Motor
    • Steering Pump Motor
Brush Alignment, Traction and Hydraulic Motors
Tests for Damaged Field and Armature7 topics
  • Test for an Open Circuit in Armature
  • Test for Short Circuit in One Armature Winding
  • Test for Short Circuit to Armature Shaft
  • Test for Open Circuit in Field Coil
  • Test for Short Circuit in Field Coil
  • Test for Short Circuit between Field and Motor Case
  • Brush Holder Test
Show all 163 sections
Troubleshooting
Table 1. Normal Commutator Surfaces
Table 2. Commutator Problems
Table 3. Brush Wear Replacement Guide
Steering Axle
Steering Axle Assembly Repair4 topics
  • Remove
    • Install
    • Remove
    • Install
Wheels and Hubs Repair (All Units)2 topics
  • Remove and Disassemble
  • Assemble and Install
Spindles and Bearings Repair (All Units)
Tie Rods Repair (All Units)
Steering Cylinder Repair1 topic
  • Clean and Inspect
Vista ® Masts
Description and Operation4 topics
  • Carriages
  • Two-Stage Mast With Limited Free-Lift
  • Two-Stage Mast With Full Free-Lift Mast
  • Three-Stage Mast With Full Free-Lift
Safety Procedures When Working Near Mast
Forks Replacement3 topics
  • Remove and Install
    • Hook Fork
    • Pin Fork
Carriage Repair
Sideshift Carriage Repair8 topics
  • Sideshift Carriage (Earlier Designs)
    • Disassemble
    • Assemble
    • Install
  • Sideshift Carriage (1993 and Later Design)
    • Remove
    • Repairs
    • Install
Weight of Mast Parts
Two-Stage Mast With Limited Free-Lift Repair
Two-Stage Mast With Full Free-Lift Repair
Three-Stage Mast With Full Free-Lift
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
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
Table 2. Ring and Pinion Tooth Contact Adjustment
Steering System for Electric Lift Trucks
Steering Wheel and Column Assembly Repair2 topics
  • Assembly Components, Remove
  • Assembly Components, Install
Power Steering Motor and Pump8 topics
  • Description
  • Remove and Disassemble, Models J2.00-3.20XM (J40-60XM, J40-60XM
  • Remove and Disassemble, Models A1.00-1.50XL (A20-30XL)
  • Remove and Disassemble, Models E1.50-2.00XMS (E25-40XMS, E25-40X
  • Assemble and Install - All models with a vertical mount except J
  • Assemble and Install, Models E1.50-2.00XMS (E25-40XMS, E25-40XM
  • Power Steering Pump, Repair
    • Seal, Replace
Hydraulic Steering Motor6 topics
  • Hydraulic Steering Motor Repairs
    • Remove
    • Disassemble
    • Clean and Inspect
    • Assemble
    • Install
Steering System Air Removal
Steering Pressure Check
Steering Chain Tension Check (Unit With MDU Only)
Optical Encoder and Activator Circuits Check
EV-100ZX™ SCR Motor Controller1 topic
  • Model Number Data For EV-100ZX Controller
Register Parameters2 topics
  • General
  • Function Numbers
Control Card, Checks and Adjustments
Handset7 topics
  • How to Check and Adjust Registers
  • How to Scroll through Fault Codes and Clear Them
  • Checks and Adjustments on Workbench
  • When Handset Is Connected to Control Card Installed In Lift Truc
  • Function Numbers 1 through 15
  • Function Numbers 16 through 30
  • Function Numbers 48 through 62
Control Cards68 topics
  • Function Number Descriptions
  • Traction Control Cards (Label Letters - ZH and ZY)
    • Function Number 1 STORED STATUS CODE
    • Function Number 2 CREEP SPEED
    • Function Number 3 CONTROLLED ACCELERATION AND 1A TIME
    • Function Number 4 CURRENT LIMIT
    • Function Number 5 PLUGGING DISTANCE (CURRENT)
    • Function Number 6 1A DROP OUT CURRENT
    • Function Number 7 FIELD WEAKENING PICK UP
    • Function Number 8 FIELD WEAKENING DROP OUT
    • Function Number 9 REGENERATIVE BRAKING CURRENT LIMIT
    • Function Number 10 REGENERATIVE BRAKING START
    • Function Number 13 SPEED LIMIT 3 (SL3)
    • Function Number 14 INTERNAL RESISTANCE COMPENSATION
    • Function Number 15 BATTERY VOLTS
    • Function Numbers GREATER THAN 15
    • Function Number 16 PEDAL POSITION PLUG
    • Function Number 17 CARD TYPE SELECTION
    • Function Number 18 STEERING PUMP TIME DELAY
    • Function Number 19 MAINTENANCE ALERT (Tens/Units)
    • Function Number 20 MAINTENANCE ALERT (Thousands/Hundreds)
    • Function Number 21 MAINTENANCE SPEED LIMIT
    • Function Numbers 22 Through 28 TEMPORARY DATA REGISTERS
    • Function Number 29 HOURMETER (Tens/Units)
    • Function Number 30 HOURMETER (Thousands/Hundreds)
    • Function Number 48 Through 62 SET LIFT TRUCK PERFORMANCE
    • Function Number 48 CONTROLLED ACCELERATION AND 1A TIME
    • Function Number 49 FIELD WEAKENING PICK UP
    • Function Number 50 SPEED LIMIT 1
    • Function Number 52 CONTROLLED ACCELERATION AND 1A TIME
    • Function Number 53 FIELD WEAKENING PICK UP
    • Function Number 54 SPEED LIMIT 1
    • Function Number 56 CONTROLLED ACCELERATION AND 1A TIME
    • Function Number 57 FIELD WEAKENING PICK UP
    • Function Number 58 SPEED LIMIT 1
    • Function Number 60 CONTROLLED ACCELERATION AND 1A TIME
    • Function Number 61 FIELD WEAKENING PICK UP
  • Pump Control Card (Label Letter ZP)
    • Function Number 1 STORED STATUS CODE
    • Function Number 2 INTERNAL RESISTANCE COMPENSATION START
    • Function Number 3 CONTROLLED ACCELERATION
    • Function Number 4 CURRENT LIMIT
    • Function Number 7 CONTROLLED ACCELERATION COMPENSATION
    • Function Number 11 SPEED LIMIT 1 (SL1) (Slow Speed) - Tilt and S
    • Function Number 12 SPEED LIMIT 2 (SL2) (Medium Speed) - Slow Lif
    • Function Number 13 SPEED LIMIT 3 (SL3)
    • Function Number 14 SPEED LIMIT 4 (SL4) Fast Lift
    • Function Numbers Greater Than 15
    • Function Number 16 INTERNAL RESISTANCE COMPENSATION
    • Function Number 17 CARD TYPE SELECTION
    • Function Numbers 18 through 28 TEMPORARY DATA REGISTERS
    • Function Number 29 HOURMETER (Tens/Units)
    • Function Number 30 HOURMETER (Thousands/Hundreds)
    • Function Number 48 CONTROLLED ACCELERATION
    • Function Number 49 SPEED LIMIT 2
    • Function Number 50 SPEED LIMIT 3
    • Function Number 52 CONTROLLED ACCELERATION
    • Function Number 53 SPEED LIMIT 2
    • Function Number 54 SPEED LIMIT 3
    • Function Number 56 CONTROLLED ACCELERATION
    • Function Number 57 SPEED LIMIT 2
    • Function Number 58 SPEED LIMIT 3
    • Function Number 60 CONTROLLED ACCELERATION
    • Function Number 61 SPEED LIMIT 2
    • Function Number 62 SPEED LIMIT 3
  • Register Parameters
  • Status Codes
  • Register Maps
Status Code Charts
EV-100ZX SCR Motor Controller Repair20 topics
  • Fuses
  • SCR, Check
  • SCR Assembly
  • Thermal Protector
  • SCR 1 Assembly, Replace
  • OFF Circuit for SCR 1
    • Reactor Assembly, Check
    • Suppressors for SCR 2 and SCR 5, Check
    • SCR 2 and SCR 5, Check
    • SCR 2 and SCR 5, Replace
    • Capacitor C1, Check
  • Diodes D3 and D4
    • Diodes D3 and D4, Check
    • Diodes D3 and D4, Replace
  • Motor Current Sensor
  • Contactors
    • Contactor, Repair
  • Control Card
  • Control Card Plugs
    • Brush Wear Indicators
Theory of Operation25 topics
  • Electronic Speed Controls
    • Silicon Controlled Rectifier (SCR)
    • Motor Circuit That Operates With Pulses
    • Traction Circuit
    • Hydraulic Pump Motor
    • SCR 1 OFF Circuit
  • Induction Current from Motor
  • Control Cards
    • Pulse Monitor Trip (PMT) (Traction Circuit Only)
    • SRO Circuit (Traction Circuit Only)
  • Sequence of Operation
    • Control Card Adjustments (Traction Circuit)
    • Accelerator Control
  • SCR Control (Hydraulic Pump Motor)
  • Circuit Protection
    • Traction Circuit Fuse
    • Current Limit
    • Thermal Protection
    • Suppressors
  • Truck Management Module (TMM1)
  • Display Panels
    • Display Panel
    • Basic Display
    • Performance Display
    • Brush Wear Indicators
Table 1. Terminal and Plug Wire Connections for Control Card ZY
Table 2. Terminal and Plug Wire Connections for Control Card ZH
Table 3. Terminal and Plug Wire Connections for Control Card ZH
Table 4. Terminal and Plug Wire Connections for Controller with
Table 5. Status Codes List
Table 6. Register Map for Control Cards ZH and ZY (Traction)
Table 7. Register Map for Control Card ZP (Hydraulic Pump)
Table 8. Terminal and Plug Wire Connections for TMM1 Module
Electrical System24 topics
  • ZX Series Display Panels
    • Display Panel
    • Basic Display Panels
    • Performance Display
    • Brush Wear Indicators
  • SEM Display Panels - Features
    • Descriptions of Common Features
    • Additional Features of Premium Display Panel
    • Descriptions of Additional Features
  • SEM Display Panel Indicators
    • All Indicator Symbols
    • Hourmeter Indicator Symbol
    • Wrench Indicator Symbol
    • Battery Indicator Symbol
    • Battery State-of-Charge (BDI)
    • Brake Fluid Too Low Symbol
    • Parking Brake Symbol
    • Fasten Seat Belt Symbol
    • LCD Screen (Standard Display Panel)
  • Additional Components of Premium Display Panel
    • Alpha Numerical Screen
    • STAR Push Button
    • Push Buttons ##1 Through ##5 - SEM
  • Other Control Components
Display Panel Components Replacement9 topics
  • ZX Panel Replacement
  • Display Panel Assembly
  • Key Switch, Replace
  • Indicator LEDs
  • Battery Indicators
  • Digital Display (Performance Display Panel Only)
  • Status Code or Performance Level Switches and Indicator LEDs (Pe
  • Basic Display Panel, Replace Parts
  • Performance Display Panel, Replace Parts
SEM Display Panel Replacement
Motor Controller (SR or SP) Replacement
Control Components Replacement25 topics
  • Start Switch, Replace
  • Brake Light Switch, Replace
  • Seat Switch, Replace
  • External Seat Switch, Adjust
  • Switch for Optional Seat Brake, Replace
  • Parking Brake Switch, Replace
  • Direction Switches (MONOTROL Pedal), Replace
  • Direction Control Switches (Steering Column), Replace
  • Direction Control Switches, E70-120XL 3 (Steering Column)
  • Brake Fluid Switch, Replace
  • Brush Wear and Overtemperature Sensors
  • Rocker Switches for Lights
  • Accelerator Position Sensor, Replace
  • On-Demand Steering Components
  • Lights, Converter, Relay, and Reverse Alarm
    • Brake, Tail, and Reverse Light Assembly, Replace
    • Flashing Light Assembly, Replace
    • Front, Rear Driving Light, or Spot Light Assemblies, Replace
    • Operator Compartment Light Assembly, Replace
    • Converter, Replace
    • Relay, Replace
    • Reverse Alarm, Replace
  • Horn and Horn Button
    • Horn Switch and Cover
  • Hydraulic Pump Switches
Control and Power Fuses Check
Brush Wear and Overtemperature Sensors Check - ZX
Thermal Sensors - SEM Check
Start Switch Adjustment2 topics
  • Accelerator Potentiometer and Start Switch E70-120XL, E70-120XL
  • Direction Switches (MONOTROL)
Brake Light Switch Adjustment
Seat Switch Check
Optional Seat Brake Switch Adjustment
Parking Brake Switch Adjustment
Direction Switches Check2 topics
  • Monotrol Pedal
  • Steering Column
Hydraulic Pump Switch Adjustment
MONOTROL or Accelerator Pedal Adjustment
Accelerator Position Sensor Adjustment
Control Card Checks and Adjustments
Register Parameter Tables
Industrial Battery
Lead-Acid Batteries
Specific Gravity
Chemical Reaction in a Cell
Electrical Terms
Battery Selection
Battery Voltage
Battery as a Counterweight
Battery Ratings1 topic
  • Kilowatt-Hours
Battery Maintenance16 topics
  • Safety Procedures
  • Maintenance Records
  • New Battery
  • Cleaning Battery
  • Adding Water to Battery
  • Hydrometer
  • Battery Temperature
  • Charging Battery
    • Types of Battery Charges
    • Methods of Charging
    • Troubleshooting Charger
    • Knowing When Battery Is Fully Charged
  • Where to Charge Batteries
    • Equipment Needed
  • Battery Connectors
  • Battery Care
Table 1. Battery Capacity Terms
Tilt Cylinders
Tilt Cylinder Repair4 topics
  • Tilt Cylinders With O-Ring or Single-Lip Seals
    • Tilt Cylinders for XM and XMS 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
Instrument Panel Indicators and Senders13 topics
  • Steering Column Gauges, Meters, and Indicators
  • LED Display Panel
    • Battery Discharge Indicators
    • Brush Wear Indicators
    • Motor Temperature Indicators
  • LX Series Display Panel
    • Hourmeter Functions
    • Battery Indicator Function
    • Status Code Function
    • Display Panel
    • Basic Display Panels
    • Performance Display
    • Brush Wear Indicators
Adjustments - General
Replacement - General Information
Meter Replacement
Sender Replacement2 topics
  • Fuel Level Sender
  • Pressure and Temperature Sender
ITW Display Panel Replacement
Column Mount Display Panel (EV-100/200ZX Motor Controllers) Repl1 topic
  • Display Panel Assembly, Replace
Dash Mount Display Panel (EV100/200ZX Motor Controllers) Replace1 topic
  • Remove and Replace
Specifications3 topics
  • Meter Specifications
  • Sender Specifications
  • Meter
Battery Indicators8 topics
  • Indicators With Meter Movements
  • Battery Indicators With LCD or LED Displays
    • Liquid Crystal Displays
    • SEM Display Panels Description
    • Light Emitting Diode Displays
    • Description LX Series
    • ZX Series Display Panels Description
    • SEVCON POWERGAUGE—42 Battery Display Panel Description
Battery Indicators Without Lift Interrupt Adjustment (Early Mode
Battery Indicators With Lift Interrupt Adjustment (Early Models)2 topics
  • Reset Potentiometer
  • Specific Gravity Alarm
Battery Indicators Without Lift Interrupt Check (Later Models)
Battery Indicators With Lift Interrupt Adjustment (Later Models)1 topic
  • Discharge Potentiometer
LED Display With Lift Interrupt
Curtis 933-1 Meter Check and Adjustment8 topics
  • Check
    • Reset Check
    • Discharge Check
    • Lockout Check
    • LEDs Do Not Illuminate
    • Hourmeter Check
    • Hourglass Icon
  • Adjust
SEVCON POWERGAUGE—42 Adjustment
Curtis Dash Display Assembly15 topics
  • Description/Features
  • Operation
  • Testing
    • Inoperative Dash Display Assembly
    • Inoperative Drive Mode Selection
    • Troubleshooting With a Programmer Handset
    • Troubleshooting Without a Programmer Handset
    • No Warnings or Faults Displayed
    • MIB/Dash Display Communication
    • Lift Interrupt
    • Lost MIB Signal Displayed
    • Lift Pump Hourmeter Input
    • Forward/Reverse Hourmeter Inputs
  • Adjust (Setup, Early Models)
  • Adjust (Setup, Later Model)
Battery Indicators Replacement
Battery Indicator Controller Replacement
Table 1. Battery Indicator (Later Models)
Table 2. SEVCON Discharge Curve Selector Positions
Table 3. Dash Display Drive Mode Inputs
Table 4. Dash Display Drive Mode Test Voltages
Table 5. Dash Display Status/Warning/Fault Test Voltages
Table 6. Testing Dash Display Status/Warning/Fault Inputs
Table 7. Battery Indicator Reset Adjustment
Lift Cylinders4 topics
  • Lowering Control Valve
  • Cylinders (General)
    • Retainer, Install
  • Cylinders (Two-Speed)
Lift Cylinder Repair10 topics
  • Lift Cylinder Removal Without Removing Mast
    • Standard Masts With Main Lift Cylinder Fastened to Crossmember o
    • Standard and Full Free-Lift Masts With Lift Cylinder Fastened to
    • Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift
  • Lift Cylinder Installation in Mast
    • Standard Masts With Main Lift Cylinder Fastened to Crossmember o
    • Standard and Full Free-Lift Masts With Lift Cylinder Fastened to
  • Chevron-Style Packing
    • Chevron-Style Packing Installation on Piston
    • Chevron-Style Packing Installation in Packing Gland
Lift Cylinders for VISTA® Masts3 topics
  • Lowering Control Valve
    • Main Lift Cylinders
    • Free-Lift Cylinder
Lift System Leak Check
Table 1. Lift Trucks with Two-Speed Lift Cylinders
Table 2. Cylinder Retainer Torque Specifications and Weight Guid
Metric and Inch (SAE) Fasteners6 topics
  • Threaded Fasteners
  • Nomenclature, Threads
  • Strength Identification
  • Cotter (Split) Pins
  • Fastener Torque Tables
  • Conversion Table
Table 1. Bolts and Screws
Table 2. Studs and Nuts
Table 3. Torque Nuts
Table 4. Torque Nuts With Nylon Insert
Table 5. Torque Values for Metric Fasteners*
Table 6. Torque Values for Inch Fasteners*
Table 7. Conversion Table for Metric and English units
Table 8. Cotter Pin Dimensional Data
Troubleshooting and Adjustments With a Computer
Computer System2 topics
  • Connect a PC to a Control Card
  • Installation
HYTECH™ Windows Software Program18 topics
  • How to Start the Program
  • DEMO Mode
  • Selecting the Communications Port
  • Verification of Controller and Lift Truck
  • Select Lift Truck Series
  • Controller Card Register Parameter List
  • How to Change a Parameter
  • How to Save a Changed Parameter File
  • How to Load a Saved Parameter File
  • How to Show and Remove Saved Parameter Files
  • How to Return to Factory Default Settings
  • How to Save Changes to Control Card
  • How to View Status Codes
  • Saving Status Codes
  • How to Show and Remove Saved Status Code Files
  • Closing and Clearing Status Code List
  • How to View Saved Register Data and Saved Status Data
  • How to Save Register Data and Status Code Data In and
GE Sentry™ Software Program4 topics
  • How to Start GE SENTRY Program
  • How to Reset MIN and MAX Display
  • Graphing Mode
  • How to Exit GE SENTRY Program
Table 1. Cable Connections - Computer to Control
Table 2. Adapter Pins (DB25F to DB9)
Table 3. Plug-Z Connection

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, 1,102 pages

Quantity one is the manual described above.

Fast free USA shipping

Ships in 1 business day.

60-day returns

Free if the mistake is ours. A manual ordered in error must come back unopened in its shrink-wrap; you pay return shipping and a 20% restocking fee applies. Return policy

Binder not included

Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.

Other editions and similar models

Hyster E70-120XL3 (C098)Service Manual · 1483862 · $79.87

Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).