Hyster A217 Parts Manual

$30.00

Type Of Manual: Parts Manual
Number of Pages: 651
Size: 26.0MB
Format: PDF

Category: Hyster Parts Manual PDF

Model List:
- A217

1. INTRODUCTION
2. GENERAL
3. LEAD-ACID BATTERIES
4. SPECIFIC GRAVITY
5. THE CHEMICAL REACTION IN A CELL
6. ELECTRICAL TERMS
7. HOW TO SELECT THE BATTERY
8. VOLTAGE OF A BATTERY
9. THE BATTERY AS A COUNTERWEIGHT
10. BATTERY RATINGS
11. Kilowatt-Hours
12. BATTERY MAINTENANCE
13. SAFETY PROCEDURES
14. MAINTENACE RECORDS
15. THE NEW BATTERY
16. HOW TO CLEAN THE BATTERY
17. HOW TO ADD WATER
18. THE HYDROMETER
19. BATTERY TEMPERATURE
20. CHARGING THE BATTERY
21. Types Of Battery Charges
22. Methods Of Charging
23. Troubleshooting The Charger
24. How To Know When The Battery Is Fully Charged
25. WHERE TO CHARGE THE BATTERIES
26. Equipment Needed
27. BATTERY CONNECTORS
28. BATTERY CARE
29. INTRODUCTION
30. GENERAL
31. DESCRIPTION
32. REMOVAL AND DISASSEMBLY
33. Replace The Load Wheels
34. Covers, Panels and Plates
35. CHANGES TO THE OVERHEAD GUARD
36. PAINTING INSTRUCTIONS
37. SAFETY LABELS
38. INTRODUCTION
39. GENERAL
40. DESCRIPTION
41. OPERATION
42. REPAIRS
43. STEERING WHEEL AND COLUMN ASSEMBLY
44. TYPE A STEERING COLUMN ASSEMBLY
45. Removal And Disassembly
46. Assembly And Installation
47. TYPE A STEERING COLUMN
48. TYPE A STEERING COLUMN
49. TYPE B STEERING COLUMN
50. Removal And Disassembly
51. Assembly And Installation
52. TYPE B STEERING COLUMN
53. Disassembly of Steering Control Unit
54. Cleaning of Steering Control Unit
55. Assembly of Steering Control Unit
56. CHECKS AND ADJUSTMENTS
57. REMOVE AIR FROM THE SYSTEM
58. TROUBLESHOOTING
59. INTRODUCTION
60. DESCRIPTION
61. OPERATION
62. Flow Control Valve
63. Relief Valve
64. REPAIRS
65. REMOVAL
66. DISASSEMBLY
67. CLEANING
68. INSPECTION
69. ASSEMBLY
70. INSTALLATION
71. CHECKS AND ADUSTMENTS
72. CHECK THE OUTPUT OF THE PUMP
73. CHECK FOR AIR IN THE HYDRAULIC SYSTEM
74. TROUBLESHOOTING
75. DC Motor Maintenance
76. Safety Precautions Maintenance and Repair
77. General
78. Brush and Commutator Inspection
79. Hydraulic Pump Motor and Traction Motor
80. Steering Pump Motor
81. Normal Commutator Surface
82. Commutator Problems
83. Brush Replacement
84. Stoning the Commutator
85. Motors Repair
86. Disassemble
87. Traction Motor and Hydraulic Pump Motor
88. Steering Pump Motor
89. Assemble
90. Traction Motor and Hydraulic Pump Motor
91. Steering Pump Motor
92. Brush Alignment, Traction and Hydraulic Motors
93. Tests for Damaged Field and Armature
94. Test for an Open Circuit in Armature
95. Test for Short Circuit in One Armature Winding
96. Test for Short Circuit to Armature Shaft
97. Test for Open Circuit in Field Coil
98. Test for Short Circuit in Field Coil
99. Test for Short Circuit between Field and Motor Case
100. Brush Holder Test
101. Troubleshooting
102. Table 1. Normal Commutator Surfaces
103. Table 2. Commutator Problems
104. Table 3. Brush Wear Replacement Guide
105. INTRODUCTION
106. GENERAL
107. DESCRIPTION
108. REMOVAL
109. Mount Type A
110. Mount Type B (A1.00-1.50XL, N40-50EA/ER, N50FA, N30-45FR, R30E/EA/EF/ES Only)
111. Mount Type B (R30DH Only)
112. DISASSEMBLY
113. ASSEMBLY
114. General
115. Installing The Spiral Bevel Pinion
116. Installing Thr Spiral Bevel Gear
117. INSTALLATION
118. Mount Type A
119. Mount Type B (A1.00-1.50XL, N40-50EA/ER, N50FA, N30-45FR, R30E/EA/EF/ES Only)
120. Mount Type B (R30DH Only)
121. CHECKS AND ADJUSTMENTS
122. ADJUST THE BACKLASH AND TOOTH CONTACT
123. ADJUST BEARING CONTACT
124. TROUBLESHOOTING
125.
125.1. INTRODUCTION
125.1.1. General
125.1.2. Description
125.2. STEERING CONTROL UNIT ASSEMBLY
125.2.1. Description
125.2.2. Removal
125.2.3. Installation
125.3. STEERING PUMP MOTOR AND PUMP
125.3.1. Description
125.3.2. Removal and Disassembly
125.3.3. Assembly and Installation
125.4. AXLE ASSEMBLY
125.4.1. General
125.4.2. Traction Motor
125.4.3. Master Dive Unit
125.4.4. Hydraulic Steering Motor
125.4.5. Caster and Caster Wheels
125.4.6. Axle Weldment
125.5. CHECKS AND ADJUSTMENTS
125.5.1. Steering Adjustments
125.6. TROUBLESHOOTING
126.
126.1. INTRODUCTION
126.1.1. General
126.2. DESCRIPTION AND OPERATION
126.2.1. Brake System
126.2.2. Brake Switch
126.3. REPAIRS
126.3.1. Brake Assembly
126.3.2. Master Cylinder And Pedal Assembly
126.3.3. Replacing Brake Switch
126.4. CHECKS AND ADJUSTMENTS
126.4.1. How To Adjust The Brake
126.4.2. Remove The Air From The Brake System
126.5. TROUBLESHOOTING
127.
127.1. INTRODUCTION
127.1.1. GENERAL
127.1.2. DESCRIPTION
127.2. LIFT PUMP
127.2.1. DESCRIPTION, LIFT PUMP
127.2.2. REPAIRS, LIFT PUMP
127.3. STEERING AND AUXILIARY PUMP
127.3.1. GENERAL
127.4. MAIN CONTROL VALVE
127.4.1. DESCRIPTION, MAIN CONTROL VALVE
127.4.2. OPERATION, MAIN CONTROL VALVE
127.4.3. REPAIRS, MAIN CONTROL VALVE
127.5. LIFT AND LOWER SOLENOID VALVE
127.5.1. DESCRIPTION, SOLENOID VALVE
127.5.2. OPERATION, SOLENOID VALVE
127.5.3. REPAIRS, SOLENOID VALVE
127.6. CHECKS AND ADJUSTMENTS
127.6.1. AIR IN THE HYDRAULIC SYSTEM
127.6.2. RELIEF VALVE ADJUSTMENTS
127.6.3. CONTROL LEVERS, LINKAGE AND SWITCHES
127.7. TROUBLESHOOTING
127.8. SPECIFICATIONS
128.
129.
129.1. ELECTRICAL WARNING DEVICES
129.1.1. GENERAL
129.1.2. DESCRIPTION
129.1.3. REPLACEMENT
130.
131.
132.
133.
133.1. INTRODUCTION
133.1.1. GENERAL
133.2. ADJUSTMENTS
133.2.1. ADJUSTING THE CONTROL CARD FOR EV-100 (N40-50EA, N40-45ER Only)
133.3. ADJUSTING THE ACCELERATOR POTENTIOMETER
133.4. ADJUSTING THE HANDLEVER BRACKET
133.5. ADJUSTING THE LIFT SWITCH
133.6. ADJUSTING THE INTERLOCK SWITCH
133.7. ADJUSTING THE TILT SWITCH
134.
135.
136.
136.1. INTRODUCTION
136.1.1. GENERAL
136.1.2. INDICATORS WITH METER MOVEMENT
136.1.3. BATTERY INDICATORS WITH LCD OR LED DISPLAYS
136.2. CHECKS AND ADJUSTMENTS
136.2.1. BATTERY INDICATORS WITHOUT LIFT INTERRUPT, EARLY MODELS
136.2.2. BATTERY INDICATORS WITH LIFT INTERRUPT, EARLY MODELS
136.2.3. BATTERY INDICATORS WITHOUT LIFT INTERRUPT, LATER MODELS
136.2.4. BATTERY INDICATORS WITH LIFT INTERRUPT, LATER MODELS
136.2.5. LED DISPLAY WITH LIFT INTERRUPT
136.2.6. CHECKING CURTIS 933-1 METER
136.2.7. ADJUSTMENT OF CURTIS 933-1 METER
136.2.8. ADJUSTMENT OF SEVCON POWERGAUGE
136.3. CURTIS DASH DISPLAY ASSEMBLY
136.3.1. Description/Features
136.3.2. Operation
136.3.3. Testing
136.4. REPAIRS
136.4.1. BATTERY INDICATORS
136.4.2. CONTROLLER FOR THE BATTERY INDICATOR
136.4.3. DISPLAY PANEL COMPONENTS
136.4.4. REPLACING SEM DISPLAY PANEL
136.4.5. SEM DISPLAY PANEL REMOVAL
137.
138.
138.1. INTRODUCTION
138.1.1. GENERAL
138.1.2. MAST WELDMENTS
138.1.3. CARRIAGES
138.2. VISTA TWO-STAGE MAST
138.2.1. DESCRIPTION
138.2.2. OPERATION
138.3. VISTA THREE-STAGE MAST
138.3.1. DESCRIPTION
138.3.2. OPERATION
139.
139.1. INTRODUCTION
139.1.1. GENERAL
139.1.2. DESCRIPTION
139.2. REPAIRS
139.2.1. MAIN CYLINDER – DISASSEMBLY
139.2.2. MAIN CYLINDER – ASSEMBLY
139.2.3. FREE-LIFT CYLINDER – DISASSEMBLY
139.2.4. FREE-LIFT CYLINDER – ASSEMBLY
139.3. TROUBLESHOOTING
140.
140.1. INTRODUCTION
140.1.1. General
140.2. SAFETY PROCEDURES
140.3. LOAD BACKREST EXTENSION, CARRIAGE, LOAD ROLLERS, SIDE ROLLERS AND FORKS
140.3.1. Load Backrest Extension – Removal And Installation
140.3.2. Carriage Assembly – Removal And Installation
140.3.3. Carriage Load Rollers – Removal And Installation
140.3.4. Side Rollers – Disassembly And Assembly
140.3.5. Fork Replacement
140.4. TWO-STAGE MAST ASSEMBLY
140.4.1. Two-Stage Mast Assembly – Removal
140.4.2. Cleaning And Inspection
140.4.3. Lift Cylinders – Removal And Installation
140.4.4. Inner Mast Assembly – Removal And Installation
140.4.5. Hoses – Replace
140.4.6. Hoses And Cable Sheaves – Replace
140.4.7. Two-Stage Lift Chains
140.4.8. Two-Stage Chain Sheave – Removal And Installation
140.4.9. Load Rollers And Wear Plugs – Removal And Installation
140.4.10. Two-Stage Mast Assembly – Installation
140.5. THREE-STAGE MAST ASSEMBLY
140.5.1. Three-Stage Mast Assembly – Removal
140.5.2. Cleaning And Inspection
140.5.3. Free-Lift Cylinder – Removal And Installation
140.5.4. Inner And Intermediate Mast Assemblies – Removal And Installation
140.5.5. Hoses – Replace
140.5.6. Hose And Cable Sheaves – Replace
140.5.7. Three-Stage Lift Chains – Removal And Installation
140.5.8. Three-Stage Chain Sheaves – Diassembly And Assembly
140.5.9. Load Rollers And Wear Plugs – Removal And Installation
140.5.10. Three-Stage Mast Assembly – Installation
140.6. CHECKS AND ADJUSTMENTS
140.6.1. Check The Operation Of The Mast
140.6.2. Check For Leaks In The Hydraulic System
140.6.3. Check Lift Chains
140.6.4. Mast Adjustments
140.6.5. Carriage Adjustments
141.
141.1. INTRODUCTION
141.1.1. GENERAL
141.1.2. DESCRIPTION
141.1.3. GENERAL
141.1.4. LOAD BACKREST EXTENSION – REMOVAL AND INSTALLATION
141.1.5. FORK REPLACEMENT
141.1.6. SIDE-SHIFT FRAME
141.1.7. OUTER FRAME OR SIDE-SHIFT APRON
141.1.8. SCISSOR ARMS – SINGLE-REACH
141.1.9. SCISSOR ARMS – DOUBLE-REACH
141.1.10. INNER FRAME ASSEMBLY
141.1.11. REACH CYLINDERS
141.1.12. TILT CYLINDERS AND TILT PIVOT ASSEMBLIES
141.1.13. SIDE-SHIFT CYLINDER
141.1.14. REACH/TILT SELECTOR VALVE
142.
143.
143.1. INTRODUCTION
143.1.1. GENERAL
143.1.2. HOW TO MOVE A DISABLED LIFT TRUCK
143.1.3. HOW TO PUT A LIFT TRUCK ON BLOCKS
143.1.4. How to Raise the Load Wheels
143.2. MAINTENANCE SCHEDULE
143.3. MAINTENANCE PRODEDURES
143.4. EVERY 8 HOURS OR DAILY
143.4.1. CHECKS BEFORE OPERATION
143.4.2. Battery
143.4.3. CHECK THE OPERATION
143.5. EVERY 350 HOURS OR TWO MONTHS
143.5.1. DIRECTION AND SPEED CONTROL
143.5.2. BRAKE FLUID
143.5.3. HYDRAULIC TANK BREATHER
143.5.4. CONTACTORS
143.5.5. MOTOR BRUSHES
143.5.6. SAFETY LABELS
143.5.7. LIFT CHAINS
143.5.8. HINGES, LEVERS AND PEDALS
143.5.9. MASTER DRIVE UNIT
143.5.10. ARTICULATION STOPS, STEERING AXLE
143.6. EVERY 2000 HOURS OR YEARLY
143.6.1. MASTER DRIVE UNIT
143.6.2. STEERING CHAIN
143.6.3. STEERING AXLE ASSEMBLY
143.6.4. BRAKE ASSEMBLY
143.6.5. REPLACE THE HYDRAULIC OIL AND FILTER
143.6.6. LOAD WHEEL BEARINGS
143.7. GENERAL PROCEDURES
143.7.1. CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM
143.7.2. HOW TO CHARGE THE BATTERY
143.7.3. HOW TO CHANGE THE BATTERY
143.7.4. HOW TO ADJUST THE BRAKE
143.8. WHEELS AND TIRE
143.8.1. HOW TO CHANGE THE DRIVE TIRE AND STEERING TIRE
143.8.2. HOW TO REPLACE THE LOAD WHEELS
143.8.3. HOW TO REPLACE THE CASTER WHEELS
143.9. BATTERY SPECIFICATIONS
144.
145.
145.1. LIFT CAPACITIES
145.2. MASTER DRIVE UNIT
145.3. CAPACITIES
145.4. CONTROL SETTINGS N40-50EA/ER – Control Card Adjustments
145.5. CONTROL SETTINGS – N30FR, N40-50FA/FR
145.6. HYDRAULIC SYSTEM SPECIFICATIONS
145.7. BATTERY SPECIFICATIONS
145.8. REACH CARRIAGE SPECIFICATIONS
146.
146.1. FIGURE 1. HYDRAULIC SCHEMATIC
146.2. FIGURE 2. ELECTRICAL SYSTEM-SCHEMATIC DIAGRAM
146.3. FIGURE 3. ELECTRICAL SYSTEM-WIRING DIAGRAM
146.4. FIGURE 4. ELECTRICAL CONTROLS-WIRING DIAGRAM
146.5. FIGURE 5. ELECTRICAL SYSTEM-CABLE DIAGRAM
146.6. FIGURE 6. HAND LEVER ASSEMBLY WIRING
146.7. FIGURE 7. ACCELERATOR ASSEMBLY WIRING

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