Hyster E70-120XL3 (C098) Forklift Service Manual
758 pages · Publication 1483862
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- Models
- E70-120XL3 (C098)
- Manual type
- Service Manual
- Pages
- 758
- Publication
- 1483862
- Condition
- Brand new
What's inside
From the manual's own table of contents: 145 sections, 483 entries. See sample pages (PDF, 264 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 145 sections
Troubleshooting
Table 1. Normal Commutator Surfaces
Table 2. Commutator Problems
Table 3. Brush Wear Replacement Guide
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 Repair1 topic
- Clean and Inspect
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
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
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
Specifications
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
Masts1 topic
- Two-Stage Mast With Full Free-Lift
Fork Replacement
Three-Stage Mast With Full Free-Lift Repair
Table 1. Tilt Cylinder Leak Check Specifications, S3.50-5.50XM (
Table 2. Hook type Carriage Chain Adjustment
Table 3. Pin-Type Carriage Chain Adjustment1 topic
- Lowering Control Valve (Velocity Fuse)
Transistor Motor Controllers (SR and SP)1 topic
- Model Number Data for Transistor Motor Controllers (SR and SP)
Motor Controller Checks and Adjustments
Checks and Adjustments Using a Handset7 topics
- General
- Connect Handset
- Start Sequence
- Check or Delete Stored Status Codes
- Returning Lift Truck to Normal Operation
- Checks and Adjustments on Workbench
- How to Check and Adjust Registers
Function Parameters Adjustments5 topics
- Function Numbers
- When Handset is Connected to Motor Controller in Lift Truck
- Function Numbers 1 through 15
- Function Numbers 16 through 30
- Function Numbers 48 through 63
Function Number Descriptions
Traction Motor Controller (Label Letter - SR)1 topic
- Functions with Premium Display Panel Only
Pump Motor Controller (Label Letter - SP)1 topic
- Status Codes
Status Code Charts
Transistor Motor Controllers Repairs11 topics
- General Maintenance Instructions
- Special Precautions
- Fuses
- Contactors
- Repair
- Contactor Driver Module
- Contactor Driver, Replace
- Motor Controller Plug
- Brush Wear Indicators
- Thermal Sensors
- Motor Controller, Replace
Parameter Tables3 topics
- Function Numbers
- Motor Controller Checks and Adjustments
- Parameter Tables
Theory of Operation34 topics
- SEM System Description
- SEM System Operation (SR Motor Controller)
- Reverse Circuit
- Performance and Efficiency
- Field Weakening
- Regenerative Braking
- Creep Speed
- Controlled Acceleration
- Current Limit
- Braking
- Regenerative Braking to Zero Speed
- Pedal Position Braking
- Auto Braking
- Auxiliary Speed Control
- Field Weakening
- Speed Limits
- Ramp Operation
- Ramp Start
- Anti-Rollback
- Steer Pump Contactor Time Delay
- Coil Drivers and Internal Coil Suppression
- System Protective Override
- SRO (Static Return to Off)
- Accelerator Volts Hold Off
- Pulse Monitor Trip (PMT)
- Thermal Protector (TP)
- Low Voltage
- SP Pump Motor Controllers
- Diagnostics
- Systems Diagnostics
- Standard Status Codes
- Stored Status Codes
- Hourmeter Readings
- Maintenance Management Capability
Table 1. Speed/Torque Compensation
Table 2. Function Map for Motor Controllers SR (Traction)
Table 3. Function Map for Motor Controllers SP (Lift Pump Motor)
Table 4. List of Status Codes
Table 5. Large (P) Plug (23-Pin) Connections/Descriptions for Mo
Table 6. Small Plug (12-Pin) Connections/Descriptions for Motor
Table 7. Traction Control - SR Transistor Control Settings, 11-I
Table 8. Traction Control - SR Transistor Control Settings, 13-I
Table 9. Traction Control - SR Transistor Control Settings, 13-n
Table 10. Hydraulic Pump - SR Transistor Control Settings (36/48
Periodic Maintenance6 topics
- Serial Number Data
- How to Move Disabled Lift Truck
- How to Tow Lift Truck
- How to Put Lift Truck on Blocks
- How to Raise Drive Tires
- How to Raise Steering Tires
Maintenance Schedule
Maintenance Procedures Every 8 Hours or Daily17 topics
- How to Make Checks with Key Switch OFF
- Tires and Wheels
- Forks
- Inspect Mast, Forks, 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
- Gauges, Horn, and Fuses
- Steering System
- Service Brakes
- Parking Brake
- Control Levers and Pedals
- Lift System Operation
Maintenance Procedures Every 500 Hours or 3 Months10 topics
- Differential and Speed Reducer
- Wheel Nuts
- Steering Axle Spindles
- Mast
- Brake Fluid
- Other Lubrication
- Seat Brake
- Electrical Inspection
- Contactors
- Motor Brushes
Maintenance Procedures Every 1000 Hours or 6 Months4 topics
- Lift Chains
- Wear Check
- Lubrication
- Forks
Maintenance Procedures Every 2000 Hours or Yearly8 topics
- Hydraulic System
- Hydraulic Tank Breather
- Change Filter for Hydraulic Oil
- Change Hydraulic Oil
- Service Brakes
- Wheel Bearings
- Steer Wheels, Lubrication
- Drive Wheels, Lubrication
Battery Maintenance2 topics
- How to Charge Battery
- How to Change Battery
Lift and Tilt System Leaks Check2 topics
- Check Lift Cylinders for Leaks
- Check Tilt Cylinders for Leaks
How to Check PMT Circuit
Welding Repairs
Overhead Guard Changes
Tires and Wheels3 topics
- Remove Wheels from Lift Truck
- Remove Tire from Wheel and Install Tire on Wheel
- Install Wheels
Battery Specifications
Table 1. Maintenance Schedule
Table 2. Hook-Type Carriage Chain Adjustment
Display Panel for SEM Controls
SEM Display Panel Features15 topics
- Descriptions of Common Features
- LED Symbol Indicators
- LCD Screen
- Battery Discharge Indicator (BDI)
- Service Reminder
- Status Codes
- Hourmeter
- Additional Features of Premium Display Panel
- Descriptions of Additional Features (Available with Premium Disp
- LCD Screen
- Operator Passwords
- Daily Check List and Service Items
- Performance Modes
- Status Code Lists
- Adjustment of BDI
SEM Display Panel Indicators9 topics
- 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 Panel3 topics
- Alphanumeric Screen
- STAR Push Button
- Push Buttons 1 Through 5
Adjustments With a Computer10 topics
- Computer System
- Connect PC to SEM Display Panel
- ITW Switches Windows Software Program (for SEM Display Panel)
- Description
- Where to Get Help
- Hardware and Software Requirements
- Install
- How to Start ITW SWITCHES Program
- Menus
- Sample Sessions
Replacement2 topics
- SEM Display Panel
- Remove and Replace
Table 1. Adapter Pins (DB25F to DB9)
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
Inside this manual
Real pages from this service manual (758 pages). Open the sample pages (PDF, 264 KB)
- Diagram, page 77: Troubleshooting
- Troubleshooting, page 572: Status Code Charts
- Specifications, page 627: Maintenance Procedures Every 1000 Hours or 6 Months
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, 758 pages
Quantity one is the manual described above.
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Other editions and similar models
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