PDF Service Manual Hyster F108 - 5 MB
This service manual provides detailed instructions for the maintenance and repair of the Hyster F108 model.
It is designed for service technicians, offering step-by-step procedures for troubleshooting and fixing various systems.
Keep your Hyster equipment in optimal working condition with this comprehensive guide.
Proper servicing is key to reliability and a long service life.
PDF Viewer
Viewer loads when you scroll here
SHARE THIS MANUAL
Download the PDF Manual
PDF viewer loading area
Text Preview from This Manual
The text below was extracted from the visible preview pages to help you confirm the manual contents before download.
--- Page 11 ---
Electrical Diagrams Table of Contents
TABLE OF CONTENTS
Diagrams, Schematics, or Arrangements ......................................................................................................... 1
Figure 1. EV-100ZX SCR Control for Traction Motor Schematic........................................................... 1
Figure 2. EV-100ZX SCR Control for Lift Pump Motor Schematic........................................................ 2
Figure 3. Contactor Control for Lift Pump Motor Schematic................................................................. 3
Figure 4. Wiring Diagram E2.00-3.20XM (E45-65XM) and N30XMH .................................................. 4
Figure 5. Wiring Diagram E2.00-3.20XM (E45-65XM) and N30XMH .................................................. 6
Figure 6. Wiring Diagram E2.00-3.20XM (E45-65XM) and N30XMH .................................................. 8
Figure 7. Controller Panel-to-Panel Wiring Connections E2.00-3.20XM (E45-65XM) and
N30XMH .................................................................................................................................................... 10
Figure 8. Controller Panel-to-Panel Wiring Connections J2.00-3.20XM (J40-60XM) .......................... 11
Figure 9. Wiring Diagram J2.00-3.20XM (J40-60XM)............................................................................ 12
Figure 10. Wiring Diagram J2.00-3.20XM (J40-60XM).......................................................................... 14
Figure 11. Wiring Diagram J2.00-3.20XM (J40-60XM) .......................................................................... 16
Figure 12. Truck Wiring Harnesses and Cables E2.00-3.20XM (E45-65XM) and N30XMH................ 18
Figure 13. Truck Power Cables E2.00-3.20XM (E45-65XM) and N30XMH .......................................... 20
Figure 14. EV-100ZX SCR Traction and Pump Motor Controllers E2.00-3.20XM (E45-65XM)
and N30XMH............................................................................................................................................. 22
Figure 15. EV-100ZX SCR Traction Motor Controller and Contactor Pump Control
E2.00-3.20XM (E45-65XM) ....................................................................................................................... 24
Figure 16. EV-100ZX SCR Traction Motor and SCR Pump Motor Controllers E2.00-3.20XM
(E45-65XM) and N30XMH........................................................................................................................ 26
Figure 17. EV-100ZX SCR Traction Motor Controller with Contactor Control of Pump Motor
E2.00-3.20XM (E45-65XM) ....................................................................................................................... 27
Figure 18. EV-100ZX Contactor Panel E2.00-3.20XM (E45-65XM) and N30XMH .............................. 28
Figure 19. Chassis and Hydraulic Linkage, Switch Wiring Details E2.00-3.20XM (E45-65XM)
and N30XMH............................................................................................................................................. 30
Figure 20. Truck Wiring Harnesses and Cables J2.00-3.20XM (J40-60XM) ......................................... 32
Figure 21. Truck Power Cables J2.00-3.20XM (J40-60XM).................................................................... 34
Figure 22. EV-100ZX SCR Traction and Pump Motor Controllers J2.00-3.20XM (J40-60XM)............ 36
Figure 23. EV-100ZX SCR Traction Motor Controller and Contactor Pump Control
J2.00-3.20XM (J40-60XM) ........................................................................................................................ 38
Figure 24. EV-100ZX SCR Traction Motor and SCR Pump Motor Controllers J2.00-3.20XM
(J40-60XM) ................................................................................................................................................ 40
Figure 25. EV-100ZX SCR Traction Motor Controller with Contactor Control of Pump Motor
J2.00-3.20XM (J40-60XM) ........................................................................................................................ 41
Figure 26. EV-100ZX Contactor Panel J2.00-3.20XM (J40-60XM)........................................................ 42
Figure 27. Chassis and Hydraulic Linkage Switch Wiring Details J2.00-3.20XM (J40-60XM)........... 44
Figure 28. Steering Column Wiring Detail.............................................................................................. 46
Figure 29. Display Panels and Plug Connectors ..................................................................................... 48
Figure 30. Detail of Battery Connectors with +12-Volt Tap ................................................................... 50
Figure 31. Lighting Schematic (Chassis)................................................................................................. 51
Figure 32. Lighting Schematic (Rear) E2.00-3.20XM (E45-65XM) and N30XMH................................ 52
Figure 33. Lighting Schematic (Rear) J2.00-3.20XM (J40-60XM) ......................................................... 53
Figure 34. Lighting Wiring Diagram E2.00-3.20XM (E45-65XM) and N30XMH ................................. 54
Figure 35. Lighting Wiring Diagram J2.00-3.20XM (J40-60XM) .......................................................... 58
This section is for the following models:
E2.00-3.20XM (E45-65XM) [F108];
J2.00-3.20XM (J40-65XM) [A216];
N30XMH [C210]
©2003 HYSTER COMPANY i
--- Page 12 ---
8000 SRM 551 Diagrams, Schematics, or Arrangements
Figure 6. Wiring Diagram E2.00-3.20XM (E45-65XM) and N30XMH
9
--- Page 13 ---
8000 SRM 551 Diagrams, Schematics, or Arrangements
Legend for Figure 12
1. TRACTION MOTOR 5. MONOTROL PEDAL
2. LIFT PUMP MOTOR 6. CONTROL LEVER SWITCHES
3. STEERING PUMP MOTOR 7. MOTOR CONTROLLERS COMPARTMENT
4. HORN 8. BATTERY COMPARTMENT
19
--- Page 14 ---
NOTES
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
29
--- Page 15 ---
8000 SRM 551 Diagrams, Schematics, or Arrangements
Legend for Figure 23
1. YEL/PINK WIRE 17. P9
2. RED/BLUE-LT AND RED/WHT WIRES 18. P5
3. CONTACTOR FOR WIRE 50 (TO DRIVER TERM. 19. P13
1) 20. 1P2
4. CONTACTOR FOR WIRE 50 (TO PUMP PB3) 21. CARD PLUG Z (STATIC PANEL SIGNALS)
5. GRN WIRE 22. 1P3
6. WHT-5 WIRE 23. TAN WIRE
7. PINK WIRE 24. P3
8. BLUE-LT WIRE 25. P10
9. CONNECTOR FOR YEL/GRN WIRE (PY11) 26. MAIN CHASSIS HARNESS
10. CARD PLUG Y (CARD-TO-CARD AND DISPLAY 27. STANDARD DISPLAY HARNESS
WIRES) 28. ENHANCED DISPLAY HARNESS
11. CARD PLUG A (INPUT SIGNAL) 29. BATTERY NEG STUD
12. TERMINAL BOARD CONNECTIONS 30. PUMP CONTACTOR DRIVER
13. 2P1 31. WIRE 10-3
14. BRN AND BRN (POWER DISCONNECT) 32. WIRE 10-4
15. RED/WHT AND PINK (SEAT SW) 33. WIRE 60
16. P14
39
--- Page 16 ---
8000 SRM 551 Diagrams, Schematics, or Arrangements
Legend for Figure 29
1. BATTERY CHANGE INDICATOR WITH LIFT 9. INDICATOR LIGHT, HYDRAULIC MOTOR
INTERRUPT 10. WARNING LIGHT, MOTOR TEMPERATURE
2. DIGITAL DISPLAY OVER LIMIT (TRACTION OR HYDRAULIC)
3. WARNING LIGHT, FASTEN SEAT BELT 11. WARNING LIGHT, SERVICE INTERVAL
4. WARNING LIGHT, BRAKE FLUID RESERVOIR 12. INDICATOR LIGHT, HOURMETER
IS LOW 13. PUSH BUTTON, DISPLAY STATUS CODES
5. WARNING LIGHT, PARKING BRAKE INDICATOR 14. PUSH BUTTON, SET PERFORMANCE LEVEL
6. INDICATOR LIGHT, STEERING PUMP MOTOR 15. PERFORMANCE LEVEL INDICATORS (FOUR
7. WARNING LIGHT, MOTOR BRUSHES LEDS)
ARE WORN (TRACTION, HYDRAULIC, OR 16. HOURMETER
STEERING) 17. VOLTMETER
8. INDICATOR LIGHT, TRACTION MOTOR
49
--- Page 17 ---
8000 SRM 551 Diagrams, Schematics, or Arrangements
Figure 35. Lighting Wiring Diagram J2.00-3.20XM (J40-60XM)
59
--- Page 18 ---
8000 SRM 551 Diagrams, Schematics, or Arrangements
Figure 3. Contactor Control for Lift Pump Motor Schematic
3
--- Page 19 ---
8000 SRM 551 Diagrams, Schematics, or Arrangements
Figure 9. Wiring Diagram J2.00-3.20XM (J40-60XM)
13
--- Page 20 ---
8000 SRM 551 Diagrams, Schematics, or Arrangements
Legend for Figure 14
1. CARD PLUG Y (CARD-TO-CARD AND DISPLAY 17. BLK/TAN
WIRES) 18. P9
2. BLUE-LT AND WHT/BLUE 19. 2P2
3. PINK AND PINK 20. P13
4. WHT AND WHT/PINK 21. P14
5. RED/BLUE-LT 22. P5
6. RED/BLUE-LT 23. 1P1
7. GRN/WHT 24. P3
8. CARD PLUG A (INPUT SIGNALS) 25. P10
9. CONNECTOR FOR 50 26. 2P3
10. CONNECTOR FOR 70 27. CARD PLUG B (CONTACTOR CONTROL
11. CONNECTOR FOR 48 SIGNAL)
12. WIRE 32 28. BLK 8 AND BLK 5
13. CARD PLUG Z (STATIC PANEL SIGNALS) 29. BLUE-DK
14. BRN AND BRN/GRN-DK 30. BLUE-DK/GRN
15. BRN/WHT 31. GRAY
16. BRN/PURPLE
23
--- Page 21 ---
8000 SRM 551 Diagrams, Schematics, or Arrangements
Legend for Figure 20
1. TRACTION MOTOR 6. DISPLAY PANEL HARNESS
2. LIFT PUMP MOTOR 7. TO INSTRUMENT PANEL
3. STEERING PUMP MOTOR 8. TO ON-DEMAND STEERING
4. HARNESS FOR TEMP. AND BWI SENSORS 9. BATTERY+ CONTROL WIRES
5. MAIN CHASSIS HARNESS
33
--- Page 22 ---
NOTES
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
43
--- Page 23 ---
8000 SRM 551 Diagrams, Schematics, or Arrangements
Figure 33. Lighting Schematic (Rear) J2.00-3.20XM (J40-60XM)
53
--- Page 24 ---
EV-100ZX™ SCR MOTOR
CONTROLLER
DESCRIPTION, ADJUSTMENTS,
TROUBLESHOOTING, REPAIRS,
AND THEORY
E1.50-1.75XM, E2.00XMS (E25-35XM, E40XMS) [D114];
E.200-3.20XM, E2.50-3.00XMS (E45-65XM, E45-50XMS) [F108];
E3.50-5.50XL (E70-120XL) [C098];
J2.00-3.20XM, J2.50XMS (J40/50/60/65XM, J50XM Short) [A216];
N30XMH [C210]
PART NO. 897636 2200 SRM 557
--- Page 25 ---
2200 SRM 557 General
A. MOTOR CONTROLLER WITH REGENERATIVE B. MOTOR CONTROLLER WITH REGENERATIVE
BRAKING, 1A BYPASS, AND SCR CONTROLLER BRAKING, 1A BYPASS, AND CONTACTOR
FOR HYDRAULIC PUMP CONTROL FOR HYDRAULIC PUMP
1. TRACTION CONTROLLER 9. FIELD WEAKENING RESISTOR
2. SCR CONTROL FOR HYDRAULIC PUMP 10. COUNTERWEIGHT
MOTOR CONTROLLER 11. ELECTRONIC DRIVER
3. HYDRAULIC PUMP MOTOR CONTACTOR 12. TRUCK MANAGEMENT MODULE (TMM1)
4. FORWARD CONTACTOR 13. FUSE 1 (TRACTION CIRCUIT)
5. REVERSE CONTACTOR 14. FUSE 2 (HYDRAULIC PUMP CIRCUIT)
6. 1A BYPASS CONTACTOR 15. FUSE PANEL (FU 7, FU 3, FU 5, FU 6)
7. REGENERATIVE BRAKING CONTACTOR 16. FUSE 4 (STEERING CIRCUIT)
8. FIELD WEAKENING CONTACTOR
Figure 2. Typical Configurations of EV-100ZX Motor Controller in J-XM Model Lift Trucks
5
--- Page 26 ---
2200 SRM 557 General
Table 4. Terminal and Plug Wire Connections for Controller with SCR Control of Traction Circuit
and SCR Control of Hydraulic Pump Motor — Control Card - Type ZP (Continued)
Plug or Wire Color or
Terminal Wire Number Function
No.
PY4 BLK-3 Instrument panel display/number 10 input (ground).
PY5 WHT-3 Instrument panel display number 2 input.
PY6 — Not used.
PY7 — Not used.
PY8 — Not used.
PY9 — Not used.
PY10 BRN/ORN Signal wire between hydraulic pump control card and traction
control card (brush wear indicators, all motors).
PY11 BRN/PNK Signal wire between hydraulic pump control card and traction
control card (brush wear indicators, all motors).
PY12 BRN/WHT Signal wire between hydraulic pump control card and traction
control card (temperature switches, hydraulic pump motor, and
traction motor).
PY13 WHT-4 Instrument panel display number 7 input.
PY14 BLK-4 Instrument panel display number 6 input.
PZ1 BLK Signal wire from SCR 1 thermal protector.
PZ2 BRN Battery negative.
PZ3 YEL Signal wire from current sensor.
PZ4 GRN Signal wire from current sensor.
PZ5 GRY Signal wire from SCR 1 thermal protector.
PZ6 — Not used.
PZ7 WHT Battery positive.
PZ8 BLU/WHT Signal wire to SCR 1 gate.
PZ9 BLU Signal wire from SCR 1 cathode.
PZ10 WHT/RED Signal wire to SCR 2 gate.
PZ11 RED Connection between filter for SCR 2 and control card.
PZ12 WHT/PUR Signal wire to SCR 5 gate.
PZ13 PUR Connection between filter for SCR 5 and control card.
PZ14 ORN Sensor wire for voltage check across capacitor C1.
15
--- Page 27 ---
2200 SRM 557 Control Cards
500 amps. The pedal position has no effect on the NOTE: There is no delay time for the contactor to
plugging distance with this setting. close after receiving the input signal from the seat
switch or the FWD/REV switch. Parameters in the
Use the following information to adjust the current 0-128 range adjust the delay after the seat switch
value: opens. Parameters in the 129-255 range adjust the
delay after the FWD/REV switch opens. Adjust the
Range 100 to 930 amps
setting to the number shown in Tables for the
Parameter Range 0 to 255 Register Parameters.
Resolution 3.2A per set unit
Function Number 19 MAINTENANCE
Example: Parameter of 20 = 164 amps ALERT (Tens/Units)
20 × 3.2A = 64A
(Push CONT and 4)
64A + 100 (range min) = 164A
This register can be set by the service person to give
a Status Code -99 when scheduled maintenance is
Function Number 17 CARD TYPE required. The range for this register is 0 to 99 hours.
SELECTION
Function Number 20 MAINTENANCE
(Push CONT and 2)
ALERT (Thousands/Hundreds)
WARNING (Push CONT and 5)
Wrong parameters entered into the register in
This register can be set by the service person to give
Function Number 17 CARD TYPE SELECTION
a Status Code -99 when scheduled maintenance is
can cause the truck to operate differently than
required. The range for this register is 100 to 9900
normal. This different operation of the truck
hours.
can cause an injury. NEVER set Function Num-
ber to a parameter that is not shown for your Function Number 21 MAINTENANCE
lift truck.
SPEED LIMIT
This register permits the selection of the card type
used for your lift truck application. (Push CONT and 6)
This register can be set by the service person to con-
Function Number 18 STEERING PUMP trol the speed limit (maximum battery volts to the
TIME DELAY motor) when the Maintenance Alert (Status Code
-99) is activated by the control card. The range for
(Push CONT and 3)
this register is 0 to 180.
WARNING Function Numbers 22 Through 28
A parameter set lower than the number shown TEMPORARY DATA REGISTERS
in the Tables for the Parameter Registers can
permit the steering pump to stop if the seat
CAUTION
switch opens momentarily during normal oper-
ation. There is no power steering if the steer- Function Number 25 (temporary storage reg-
ing pump stops. The sudden and difficult steer- ister for fault data) and Function Number 26
ing effort that is not expected can cause injury (temporary storage register for battery charge
or property damage. data) must not be changed by the user to any
number above zero. Any number above zero
This register selects input for the steering pump can cause the instrument panel display to not
contactor. Closing the seat switch or the FWD/REV operate correctly and the lift truck can become
switch can be the input. The parameter also sets the disabled.
time delay for the contactor to open after the switch
opens. These registers can be read with the Handset, but the
data in them changes during lift truck operation. Do
not change the parameters in registers for Function
25
--- Page 28 ---
2200 SRM 557 Troubleshooting
Table 5. Status Codes List (Continued) REGISTER MAPS
The information in the Register Maps shown in Ta-
Status ble 6 and Table 7 is not needed by most service peo-
Description
Code ple. This additional technical information is for ser-
-149 SCR 5 does not go ON correctly vice engineers who have special troubleshooting re-
quirements. These registers and their descriptions
-150 C1 volts low are designed by the General Electric Company. Many
-151 C1 volts high with high motor current of these registers are programmed by Hyster Com-
pany to do certain functions. These register maps as
-152 C1 volts high with low motor current programmed by Hyster Company are shown in the
-154 Short circuit in electronic driver for Parameter Tables.
the hydraulic pump contactor or 1A
NOTE: The number of the EEPROM register is off-
contactor
set by one from the PC Register Number and the
-157 Polarity check, current sensor output Function Number in the Register Map Tables. The
voltage EEPROM begins its count from zero (0) while the PC
and Handset count from one (1).
* Not used on all models of lift trucks. Status
Codes in this group will flash on the display. NOTE: EEPROM = Electrically Erasable Pro-
NOTE: Motor speed is decreased when a status grammable Read Only Memory
code -41 is indicated.
Table 6. Register Map for Control Cards ZH and ZY (Traction)
EEPROM PC Handset
Register Register (HS) Description Access By: Restrictions
Number Number Number
0 1 1 Fault Code HS or PC Erases when battery
is disconnected
1 2 2 Creep HS or PC None
2 3 3 Controlled Acceleration HS or PC None
3 4 4 Current Limit HS or PC None
4 5 5 Current Limit (Plugging) HS or PC None
5 6 6 1A Dropout HS or PC None
6 7 7 FW Pickup HS or PC None
7 8 8 FW Dropout HS or PC None
8 9 9 Regenerative Braking HS or PC None
Current Limit
9 10 10 Regenerative Start HS or PC None
10 11 11 Speed Limit 1 HS or PC None
11 12 12 Speed Limit 2 HS or PC None
12 13 13 Speed Limit 3 HS or PC None
13 14 14 Battery Voltage HS or PC None
Compensation
14 15 15 Battery Voltage Selection HS or PC None
35
--- Page 29 ---
2200 SRM 557 Troubleshooting
Table 7. Register Map for Control Card ZP (Hydraulic Pump) (Continued)
Handset
EEPROM PC
(HS)
Register Function Function Access By: Restrictions
Function
Number Number
Number
110 111 62 Instrument Panel HS or PC None
Display SL4-4
111 112 NOT USED PC Only
112 113 Secure Hourmeter PC Only Read Only
(Tens/Units)
113 114 Secure Hourmeter PC Only Read Only
(Thousands/Hundreds)
114 115 Secure Auxiliary PC Only Read Only
Hourmeter (Thousands/
Hundreds)
115 116 Secure Auxiliary PC Only Read Only
Hourmeter (Thousands/
Hundreds)
116 117 PC Only GE Use Only
117 118 PC Only GE Use Only
118 119 PC Only GE Use Only
119 120 PC Only GE Use Only
120 121 PC Only None
121 122 PC Only None
122 123 PC Only None
123 124 PC Only None
124 125 PC Only None
125 126 PC Only None
126 127 PC Only None
127 128 PC Only None
45
--- Page 30 ---
2200 SRM 557 Status Code Charts
Status Code Description Cause of Status Indication
The START switch is closed when the This Status Code is indicated when TB2
-11 key switch is closed and voltage is is greater than 60% of battery voltage
applied to the control card. when the key switch is closed.
Memory Recall Indication of Fault
No Forward or Reverse contactor does
not close.
Possible Cause
START switch needs adjustment
or is damaged.
Input voltage must be less than 60% of
battery voltage when the key switch is
closed. Replace or adjust the START
switch.
Circuit Short circuit between battery positive
Traction (ZX and TB2 in START switch circuit.
Control Card
Disconnect the wire from TB2. Check for
Only)
a short circuit between the end of the wire
and the battery positive. Resistance must
be greater than 4.7 kohms.
Control card malfunction.
Disconnect the wire from TB3 and measure
the voltage from TB3 to battery negative.
If the voltage is not zero, replace the
control card.
55
--- Page 31 ---
2200 SRM 557 Status Code Charts
Status Code Description Cause of Status Indication
SCR 2 does not go to ON correctly. This Status Code is indicated when SCR 2
-47 (Also see Status Code -25). has a failure and does not go ON.
Memory Recall Indication of Fault
Yes Forward or Reverse contactors open
and close, then close only when the key
switch is opened and closed.
Possible Cause
Malfunction of SCR 2 circuit.
Check that SCR 2 goes ON with a gate
signal.
Circuit Check for an open circuit or loose
Traction connection between SCR 2 gate and PZ10
(white/red wire).
Check for an open circuit or loose
connection between SCR 1 and C1 and
through the SCR 2 circuit.
Malfunction of Forward or Reverse
contactors.