Hyster C210 (N30XMH) Service Manual - Image 2

Hyster C210 (N30XMH) Service Manual - Image 3

Hyster C210 (N30XMH) Service Manual - Image 4

Hyster C210 (N30XMH) Service Manual - Image 5

Hyster C210 (N30XMH) Service Manual

$30.00

Type Of Manual: Service Manual
Number of Pages: 746
Size: 34.8MB
Format: PDF

Category: Hyster Service Manual PDF

Model List:
- C210 (N30XMH)

1. _2
1.1. INTRODUCTION
1.1.1. GENERAL
1.1.2. LEAD-ACID BATTERIES
1.1.3. SPECIFIC GRAVITY
1.1.4. THE CHEMICAL REACTION IN A CELL
1.2. ELECTRICAL TERMS
1.2.1. HOW TO SELECT THE BATTERY
1.2.2. VOLTAGE OF A BATTERY
1.2.3. THE BATTERY AS A COUNTERWEIGHT
1.2.4. BATTERY RATINGS
1.3. BATTERY MAINTENANCE
1.3.1. SAFETY PROCEDURES
1.3.2. MAINTENACE RECORDS
1.3.3. THE NEW BATTERY
1.3.4. HOW TO CLEAN THE BATTERY
1.3.5. HOW TO ADD WATER
1.3.6. THE HYDROMETER
1.3.7. BATTERY TEMPERATURE
1.3.8. CHARGING THE BATTERY
1.3.9. WHERE TO CHARGE THE BATTERIES
1.3.10. BATTERY CONNECTORS
1.3.11. BATTERY CARE
1.4. INTRODUCTION
1.4.1. GENERAL
1.4.2. DESCRIPTION
1.5. REPAIRS
1.5.1. OVERHEAD GUARD
1.5.2. BATTERY RESTRAINT AND SEAT ASSEMBLY
1.5.3. COUNTERWEIGHT
1.5.4. TRACTION MOTOR
1.5.5. HYDRAULIC TANK
1.5.6. PAINTING INSTRUCTIONS
1.5.7. LABEL REPLACEMENT
2. _2
2.1. DC Motor Maintenance
2.2. Safety Precautions Maintenance and Repair
2.3. General
2.4. Brush and Commutator Inspection
2.5. Hydraulic Pump Motor and Traction Motor
2.6. Steering Pump Motor
2.7. Normal Commutator Surface
2.8. Commutator Problems
2.9. Brush Replacement
2.10. Stoning the Commutator
2.11. Motors Repair
2.12. Disassemble
2.13. Traction Motor and Hydraulic Pump Motor
2.14. Steering Pump Motor
2.15. Assemble
2.16. Traction Motor and Hydraulic Pump Motor
2.17. Steering Pump Motor
2.18. Brush Alignment, Traction and Hydraulic Motors
2.19. Tests for Damaged Field and Armature
2.20. Test for an Open Circuit in Armature
2.21. Test for Short Circuit in One Armature Winding
2.22. Test for Short Circuit to Armature Shaft
2.23. Test for Open Circuit in Field Coil
2.24. Test for Short Circuit in Field Coil
2.25. Test for Short Circuit between Field and Motor Case
2.26. Brush Holder Test
2.27. Troubleshooting
2.28. Table 1. Normal Commutator Surfaces
2.29. Table 2. Commutator Problems
2.30. Table 3. Brush Wear Replacement Guide
3.
3.1. INTRODUCTION
3.1.1. GENERAL
3.1.2. DESCRIPTION
3.2. REPAIRS
3.2.1. REMOVAL OF THE DRIVE AXLE
3.2.2. CLEANING
3.2.3. INSPECTION
3.2.4. ASSEMBLY
3.2.5. INSTALLATION OF THE DRIVE AXLE ASSEMBLY
3.3. TROUBLESHOOTING
3.4. TORQUE SPECIFICATIONS
4.
4.1. INTRODUCTION
4.1.1. GENERAL
4.1.2. DESCRIPTION
4.2. REPAIRS
4.2.1. STEERING AXLE ASSEMBLY
4.2.2. SPINDLES, BEARINGS, AND TIE RODS
4.2.3. STEERING CYLINDER
4.3. TROUBLESHOOTING
4.4. TORQUE SPECIFICATIONS
5.
5.1. STEERING SYSTEM
5.1.1. GENERAL
5.1.2. DESCRIPTION
5.1.3. STEERING WHEEL AND COLUMN ASSEMBLY
5.2. POWER STEERING MOTOR AND PUMP
5.2.1. DESCRIPTION
5.2.2. REMOVAL AND DISASSEMBLY, E1.25-3.00XL (E25-60XL), J2.00-3.00XL (J40-60XL), E2.00-3.20XM (E45-65XM)
5.2.3. REMOVAL AND DISASSEMBLY, E3.50-5.50XL (E70-120XL, E70-120XL3)
5.2.4. REMOVAL AND DISASSEMBLY, J2.00-3.20XM (J40-65XM)
5.2.5. REMOVAL AND DISASSEMBLY, A1.00-1.50XL (A20-30XL)
5.2.6. REMOVAL AND DISASSEMBLY, E1.50-2.00XMS (E25-40XMS)
5.2.7. ASSEMBLY AND INSTALLATION All models with a verticle mount except the J2.00-3.20XM (J40-65M)
5.2.8. ASSEMBLY AND INSTALLATION, J2.00-3.20XM (J40-65XM)
5.2.9. ASSEMBLY AND INSTALLATION, E1.50-2.00XMS (E25-40XMS)
5.2.10. REPAIRS, POWER STEERING PUMP
5.3. HYDRAULIC STEERING MOTOR
5.3.1. DESCRIPTION
5.3.2. REPAIRS, HYDRAULIC STEERING MOTOR
5.4. CHECKS AND ADJUSTMENTS
5.4.1. AIR IN THE STEERING SYSTEM
5.4.2. CHECK STEERING PRESSURE
5.4.3. CHECK THE TENSION OF THE STEERING CHAIN (Units With MDU Only)
5.4.4. CHECK OPTIONAL ENCODER AND ACTIVATOR CIRCUITS
5.5. TROUBLESHOOTING
6.
6.1. INTRODUCTION
6.1.1. GENERAL
6.1.2. DESCRIPTION
6.1.3. OPERATION
6.2. REPAIRS
6.2.1. STEERING WHEEL AND COLUMN ASSEMBLY
6.3. CHECKS AND ADJUSTMENTS
6.3.1. REMOVE AIR FROM THE SYSTEM
6.4. TROUBLESHOOTING
7.
7.1. INTRODUCTION
7.1.1. GENERAL
7.1.2. DESCRIPTION AND OPERATION
7.2. REPAIRS
7.2.1. ELECTRIC BRAKE
7.2.2. BRAKE SWITCH
7.3. TROUBLESHOOTING
8.
8.1. INTRODUCTION
8.1.1. GENERAL
8.1.2. DESCRIPTION AND OPERATION
8.1.3. SERVICE BRAKES
8.1.4. PARKING BRAKE
8.1.5. MASTER CYLINDER
8.1.6. SEAT BRAKE ASSEMBLY
8.2. CHECKS AND ADJUSTMENTS
8.2.1. ADJUST THE SERVICE BRAKES
8.2.2. ADJUST THE BRAKE PEDAL
8.2.3. ADJUST THE MASTER CYLINDER
8.2.4. REMOVE THE AIR FROM THE BRAKE SYSTEM
8.2.5. TEST THE PARKING BRAKE NOT APPLIED WARNING
8.3. TROUBLESHOOTING
8.4. TORQUE SPECIFICATIONS
9.
9.1. INTRODUCTION
9.1.1. GENERAL
9.1.2. DESCRIPTION
9.1.3. OPERATION
9.2. REPAIRS
9.2.1. HYDRAULIC TANK
9.2.2. FILTER REPLACEMENT
9.2.3. HYDRAULIC PUMP
9.2.4. MAIN CONTROL VALVE
9.2.5. STEERING PUMP
9.2.6. ROTARY ACTUATOR VALVE
9.2.7. STEERING CONTROL UNIT
9.2.8. STEERING CYLINDER
9.3. CHECKS AND ADJUSTMENTS
9.3.1. MAIN CONTROL VALVE
9.3.2. STEERING RELIEF VALVE
9.4. TROUBLESHOOTING CHART
9.5. SPECIFICATIONS
10.
10.1. INTRODUCTION
10.1.1. GENERAL
10.1.2. DESCRIPTION
10.1.3. OPERATION
10.1.4. Lift Section (See FIGURE 3.)
10.1.5. Auxiliary Section
10.1.6. Relief Valve (See FIGURE 5.)
10.2. REPAIRS
10.2.1. MAIN CONTROL VALVE
10.2.2. Removal (See FIGURE 8. And FIGURE 9.)
10.2.3. Disassembly (See FIGURE 6.)
10.2.4. Cleaning And Inspection
10.2.5. Assembly (See FIGURE 6.)
10.2.6. Installation, (See FIGURE 7. And FIGURE 8.)
10.2.7. CONTROL LEVER LINKAGE
10.2.8. Removal (See FIGURE 9.)
10.2.9. Disassembly (See FIGURE 9.)
10.2.10. Assembly And Installation (See FIGURE 9.)
10.2.11. CONTROL VALVE LINKAGE
10.2.12. Removal And Disassembly (See FIGURE 10.)
10.2.13. Assembly And Installation (See FIGURE 10.)
10.3. CHECKS AND ADJUSTMENTS
10.3.1. PRESSURE RELIEF VALVES
10.3.2. Primary Relief Valve (See FIGURE 12.)
10.3.3. Secondary Relief Valve (See FIGURE 12.)
10.4. TROUBLESHOOTING
10.5. TROUBLESHOOTING
11.
12.
12.1. INTRODUCTION
12.1.1. GENERAL
12.2. DESCRIPTION
12.2.1. GENERAL
12.2.2. STEERING COLUMN GAUGES, METERS AND INDICATORS
12.2.3. LED DISPLAY PANEL
12.2.4. LX SERIES DISPLAY PANEL
12.2.5. ZX SERIES DISPLAY PANELS
12.3. CHECKS AND ADJUSTMENTS
12.3.1. GENERAL
12.4. REPLACEMENT
12.4.1. GENERAL
12.4.2. METER REPLACEMENT
12.4.3. SENDER REPLACEMENT
12.4.4. DISPLAY PANEL
12.4.5. DISPLAY PANELS FOR THE EV – 100/200ZX MOTOR CONTROLLERS, COLUMN MOUNT
12.4.6. DISPLAY PANELS FOR THE EV-100/200ZX MOTOR CONTROLLERS, DASH MOUNT
12.5. SPECIFICATIONS
12.6. TROUBLESHOOTING
13.
14.
14.1. Electrical System
14.2. Safety Precautions Maintenance and Repair
14.3. General
14.4. Description
14.5. ZX Series Display Panels
14.6. Display Panel
14.7. Basic Display Panels
14.8. Performance Display
14.9. Brush Wear Indicators
14.10. SEM Display Panels – Features
14.11. Descriptions of Common Features
14.12. Additional Features of Premium Display Panel
14.13. Descriptions of Additional Features
14.14. SEM Display Panel Indicators
14.15. All Indicator Symbols
14.16. Hourmeter Indicator Symbol
14.17. Wrench Indicator Symbol
14.18. Battery Indicator Symbol
14.19. Battery State-of-Charge (BDI)
14.20. Brake Fluid Too Low Symbol
14.21. Parking Brake Symbol
14.22. Fasten Seat Belt Symbol
14.23. LCD Screen (Standard Display Panel)
14.24. Additional Components of Premium Display Panel
14.25. Alpha Numerical Screen
14.26. STAR Push Button
14.27. Push Buttons 1 Through 5 – SEM
14.28. Other Control Components
14.29. Display Panel Components Replacement
14.30. ZX Panel Replacement
14.31. Display Panel Assembly
14.32. Key Switch, Replace
14.33. Indicator LEDs
14.34. Battery Indicators
14.35. Digital Display (Performance Display Panel Only)
14.36. Status Code or Performance Level Switches and Indicator LEDs (Pe
14.37. Basic Display Panel, Replace Parts
14.38. Performance Display Panel, Replace Parts
14.39. SEM Display Panel Replacement
14.40. Motor Controller (SR or SP) Replacement
14.41. Control Components Replacement
14.42. Start Switch, Replace
14.43. Brake Light Switch, Replace
14.44. Seat Switch, Replace
14.45. External Seat Switch, Adjust
14.46. Switch for Optional Seat Brake, Replace
14.47. Parking Brake Switch, Replace
14.48. Direction Switches (MONOTROL Pedal), Replace
14.49. Direction Control Switches (Steering Column), Replace
14.50. Direction Control Switches, E70-120XL 3 (Steering Column)
14.51. Brake Fluid Switch, Replace
14.52. Brush Wear and Overtemperature Sensors
14.53. Rocker Switches for Lights
14.54. Accelerator Position Sensor, Replace
14.55. On-Demand Steering Components
14.56. Lights, Converter, Relay, and Reverse Alarm
14.57. Brake, Tail, and Reverse Light Assembly, Replace
14.58. Flashing Light Assembly, Replace
14.59. Front, Rear Driving Light, or Spot Light Assemblies, Replace
14.60. Operator Compartment Light Assembly, Replace
14.61. Converter, Replace
14.62. Relay, Replace
14.63. Reverse Alarm, Replace
14.64. Horn and Horn Button
14.65. Horn Switch and Cover
14.66. Hydraulic Pump Switches
14.67. Control and Power Fuses Check
14.68. Brush Wear and Overtemperature Sensors Check – ZX
14.69. Thermal Sensors – SEM Check
14.70. Start Switch Adjustment
14.71. Accelerator Potentiometer and Start Switch E70-120XL, E70-120XL
14.72. E70-120XL
14.73. E70-120XL 3
14.74. Direction Switches (MONOTROL)
14.75. Brake Light Switch Adjustment
14.76. Seat Switch Check
14.77. Optional Seat Brake Switch Adjustment
14.78. Parking Brake Switch Adjustment
14.79. Direction Switches Check
14.80. Monotrol Pedal
14.81. Steering Column
14.82. Hydraulic Pump Switch Adjustment
14.83. MONOTROL or Accelerator Pedal Adjustment
14.84. Accelerator Position Sensor Adjustment
15.
16.
17.
17.1. INTRODUCTION
17.1.1. GENERAL
17.1.2. MAST WELDMENTS
17.1.3. CARRIAGES
17.2. VISTA TWO-STAGE MAST
17.2.1. DESCRIPTION
17.2.2. OPERATION
17.3. VISTA THREE-STAGE MAST
17.3.1. DESCRIPTION
17.3.2. OPERATION
18.
18.1. INTRODUCTION
18.1.1. GENERAL
18.1.2. DESCRIPTION
18.2. REPAIRS
18.2.1. MAIN CYLINDER – DISASSEMBLY
18.2.2. MAIN CYLINDER – ASSEMBLY
18.2.3. FREE-LIFT CYLINDER – DISASSEMBLY
18.2.4. FREE-LIFT CYLINDER – ASSEMBLY
18.3. TROUBLESHOOTING
19.
19.1. INTRODUCTION
19.1.1. General
19.2. SAFETY PROCEDURES
19.3. LOAD BACKREST EXTENSION, CARRIAGE, LOAD ROLLERS, SIDE ROLLERS AND FORKS
19.3.1. Load Backrest Extension – Removal And Installation
19.3.2. Carriage Assembly – Removal And Installation
19.3.3. Carriage Load Rollers – Removal And Installation
19.3.4. Side Rollers – Disassembly And Assembly
19.3.5. Fork Replacement
19.4. TWO-STAGE MAST ASSEMBLY
19.4.1. Two-Stage Mast Assembly – Removal
19.4.2. Cleaning And Inspection
19.4.3. Lift Cylinders – Removal And Installation
19.4.4. Inner Mast Assembly – Removal And Installation
19.4.5. Hoses – Replace
19.4.6. Hoses And Cable Sheaves – Replace
19.4.7. Two-Stage Lift Chains
19.4.8. Two-Stage Chain Sheave – Removal And Installation
19.4.9. Load Rollers And Wear Plugs – Removal And Installation
19.4.10. Two-Stage Mast Assembly – Installation
19.5. THREE-STAGE MAST ASSEMBLY
19.5.1. Three-Stage Mast Assembly – Removal
19.5.2. Cleaning And Inspection
19.5.3. Free-Lift Cylinder – Removal And Installation
19.5.4. Inner And Intermediate Mast Assemblies – Removal And Installation
19.5.5. Hoses – Replace
19.5.6. Hose And Cable Sheaves – Replace
19.5.7. Three-Stage Lift Chains – Removal And Installation
19.5.8. Three-Stage Chain Sheaves – Diassembly And Assembly
19.5.9. Load Rollers And Wear Plugs – Removal And Installation
19.5.10. Three-Stage Mast Assembly – Installation
19.6. CHECKS AND ADJUSTMENTS
19.6.1. Check The Operation Of The Mast
19.6.2. Check For Leaks In The Hydraulic System
19.6.3. Check Lift Chains
19.6.4. Mast Adjustments
19.6.5. Carriage Adjustments
20.
20.1. INTRODUCTION
20.1.1. GENERAL
20.1.2. DESCRIPTION
20.1.3. ATTACHMENT REMOVAL
20.1.4. DISASSEMBLY
20.1.5. ASSEMBLY
20.2. CHECKS AND ADJUSTMENTS
20.2.1. THRUST ROLLERS ON THE SIDE SHIFT CARRIAGE
20.2.2. THRUST ROLLERS ON THE BOOM
20.2.3. LOAD ROLLERS ON THE BOOM
20.2.4. TRAVERSE CHAIN ADJUSTMENT
20.3. TROUBLESHOOTING
20.3.1. SPECIFICATIONS

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