Hyster A216 Parts Manual

$30.00

Type Of Manual: Parts Manual
Number of Pages: 904
Size: 38.5MB
Format: PDF

Category: Hyster Parts Manual PDF

Model List:
- A216

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. Main Frame
33. Other Frame Weldments
34. Battery Restraint/Hood Frame
35. Overhead Guard
36. REPAIRS
37. OVERHEAD GUARD
38. Removal
39. Installation
40. BATTERY RESTRAINT AND SEAT ASSEMBLY
41. Removal
42. COUNTERWEIGHT
43. Counterweight Removal
44. Counterweight Installation
45. TRACTION MOTOR
46. Motor Removal
47. Motor Installation
48. HYDRAULIC TANK
49. Tank Removal
50. Tank Inspection
51. Tank Repairs, Small Leaks
52. Tank Repairs, Large Leaks
53. Tank Cleaning
54. Steam Method Of Cleaning Tank
55. Chemical Solution Method Of Cleaning Tank
56. Additional Preparations For Tank Repair
57. Tank Installation (See FIGURE 10.)
58. PAINTING INSTRUCTIONS
59. LABEL REPLACEMENT
60. DC Motor Maintenance
61. Safety Precautions Maintenance and Repair
62. General
63. Brush and Commutator Inspection
64. Hydraulic Pump Motor and Traction Motor
65. Steering Pump Motor
66. Normal Commutator Surface
67. Commutator Problems
68. Brush Replacement
69. Stoning the Commutator
70. Motors Repair
71. Disassemble
72. Traction Motor and Hydraulic Pump Motor
73. Steering Pump Motor
74. Assemble
75. Traction Motor and Hydraulic Pump Motor
76. Steering Pump Motor
77. Brush Alignment, Traction and Hydraulic Motors
78. Tests for Damaged Field and Armature
79. Test for an Open Circuit in Armature
80. Test for Short Circuit in One Armature Winding
81. Test for Short Circuit to Armature Shaft
82. Test for Open Circuit in Field Coil
83. Test for Short Circuit in Field Coil
84. Test for Short Circuit between Field and Motor Case
85. Brush Holder Test
86. Troubleshooting
87. Table 1. Normal Commutator Surfaces
88. Table 2. Commutator Problems
89. Table 3. Brush Wear Replacement Guide
90.
90.1. INTRODUCTION
90.2. REPAIRS
90.3. TROUBLESHOOTING
90.4. TORQUE SPECIFICATIONS
91.
91.1. INTRODUCTION
91.2. REPAIRS
91.3. TORQUE SPECIFICATIONS
91.4. TROUBLESHOOTING
92.
92.1. STEERING SYSTEM
92.2. POWER STEERING MOTOR AND PUMP
92.3. HYDRAULIC STEERING MOTOR
92.4. CHECKS AND ADJUSTMENTS
92.5. TROUBLESHOOTING
93.
93.1. INTRODUCTION
93.2. REPAIRS
93.3. CHECKS AND ADJUSTMENTS
93.4. TROUBLESHOOTING
94.
94.1. INTRODUCTION
94.2. REPAIRS
94.3. CHECKS AND ADJUSTMENTS
94.4. TROUBLESHOOTING
95.
95.1. INTRODUCTION
95.2. CHECKS AND ADJUSTMENTS
95.3. TROUBLESHOOTING
95.4. TORQUE SPECIFICATIONS
96.
96.1. INTRODUCTION
96.2. REPAIRS
96.3. CHECKS AND ADJUSTMENTS
96.4. TROUBLESHOOTING CHART
96.5. SPECIFICATIONS
97.
97.1. INTRODUCTION
97.2. REPAIRS
97.3. CHECKS AND ADJUSTMENTS
97.4. TROUBLESHOOTING
98.
99.
99.1. INTRODUCTION
99.2. DESCRIPTION
99.3. CHECKS AND ADJUSTMENTS
99.4. REPLACEMENT
99.5. SPECIFICATIONS
99.6. TROUBLESHOOTING
100.
100.1. ELECTRICAL WARNING DEVICES
101.
102.
102.1. Electrical System
102.2. Safety Precautions Maintenance and Repair
102.3. General
102.4. Description
102.5. ZX Series Display Panels
102.6. Display Panel
102.7. Basic Display Panels
102.8. Performance Display
102.9. Brush Wear Indicators
102.10. SEM Display Panels – Features
102.11. Descriptions of Common Features
102.12. Additional Features of Premium Display Panel
102.13. Descriptions of Additional Features
102.14. SEM Display Panel Indicators
102.15. All Indicator Symbols
102.16. Hourmeter Indicator Symbol
102.17. Wrench Indicator Symbol
102.18. Battery Indicator Symbol
102.19. Battery State-of-Charge (BDI)
102.20. Brake Fluid Too Low Symbol
102.21. Parking Brake Symbol
102.22. Fasten Seat Belt Symbol
102.23. LCD Screen (Standard Display Panel)
102.24. Additional Components of Premium Display Panel
102.25. Alpha Numerical Screen
102.26. STAR Push Button
102.27. Push Buttons 1 Through 5 – SEM
102.28. Other Control Components
102.29. Display Panel Components Replacement
102.30. ZX Panel Replacement
102.31. Display Panel Assembly
102.32. Key Switch, Replace
102.33. Indicator LEDs
102.34. Battery Indicators
102.35. Digital Display (Performance Display Panel Only)
102.36. Status Code or Performance Level Switches and Indicator LEDs (Pe
102.37. Basic Display Panel, Replace Parts
102.38. Performance Display Panel, Replace Parts
102.39. SEM Display Panel Replacement
102.40. Motor Controller (SR or SP) Replacement
102.41. Control Components Replacement
102.42. Start Switch, Replace
102.43. Brake Light Switch, Replace
102.44. Seat Switch, Replace
102.45. External Seat Switch, Adjust
102.46. Switch for Optional Seat Brake, Replace
102.47. Parking Brake Switch, Replace
102.48. Direction Switches (MONOTROL Pedal), Replace
102.49. Direction Control Switches (Steering Column), Replace
102.50. Direction Control Switches, E70-120XL 3 (Steering Column)
102.51. Brake Fluid Switch, Replace
102.52. Brush Wear and Overtemperature Sensors
102.53. Rocker Switches for Lights
102.54. Accelerator Position Sensor, Replace
102.55. On-Demand Steering Components
102.56. Lights, Converter, Relay, and Reverse Alarm
102.57. Brake, Tail, and Reverse Light Assembly, Replace
102.58. Flashing Light Assembly, Replace
102.59. Front, Rear Driving Light, or Spot Light Assemblies, Replace
102.60. Operator Compartment Light Assembly, Replace
102.61. Converter, Replace
102.62. Relay, Replace
102.63. Reverse Alarm, Replace
102.64. Horn and Horn Button
102.65. Horn Switch and Cover
102.66. Hydraulic Pump Switches
102.67. Control and Power Fuses Check
102.68. Brush Wear and Overtemperature Sensors Check – ZX
102.69. Thermal Sensors – SEM Check
102.70. Start Switch Adjustment
102.71. Accelerator Potentiometer and Start Switch E70-120XL, E70-120XL
102.72. E70-120XL
102.73. E70-120XL 3
102.74. Direction Switches (MONOTROL)
102.75. Brake Light Switch Adjustment
102.76. Seat Switch Check
102.77. Optional Seat Brake Switch Adjustment
102.78. Parking Brake Switch Adjustment
102.79. Direction Switches Check
102.80. Monotrol Pedal
102.81. Steering Column
102.82. Hydraulic Pump Switch Adjustment
102.83. MONOTROL or Accelerator Pedal Adjustment
102.84. Accelerator Position Sensor Adjustment
103.
104.
105.
105.1. EV-100 TRANSISTOR MOTOR CONTROLLER, Parameter Tables
106.
106.1. TROUBLESHOOTING AND ADJUSTMENTS WITH A COMPUTER For EV-100ZX, EV-T100, SR (SEM) And SP Motor Controllers
107.
108.
109.
109.1. INTRODUCTION
110.
110.1. INTRODUCTION
110.2. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
110.3. REPAIRS
110.4. CHECKS AND ADJUSTMENTS
110.5. TROUBLESHOOTING
111.
112.
113.
113.1. INTRODUCTION
113.2. MAINTENANCE SCHEDULE
113.3. MAINTENANCE PROCEDURES
113.4. EVERY 8 HOURS OR DAILY
113.5. EVERY 350 HOURS OR THREE MONTHS
113.6. EVERY 2000 HOURS OR YEARLY
113.7. GENERAL PROCEDURE
113.8. REFERENCE TABLE
114.
114.1. COUNTERWEIGHTS
114.2. HYDRAULIC SYSTEM
114.3. WHEELS AND TIRES
114.4. BATTERY SPECIFICATIONS – E2.00-3.20XM (E45-65XM, E45-XM2, N30XMH, N30XMH2)
114.5. BATTERY SPECIFICATIONS – J2.00-3.20XM (J40-65XM, J40-65XM2)
114.6. CAPACITIES
114.7. MOVEMENT RATES (MAXIMUM) FOR TILT CYLINDERS
114.8. E45-65XM MAST SPEEDS (36 or 48 Volt) Americas
114.9. E40-65XM, E40-65XM2, N30XMH2 MAST SPEEDS (36 or 48 Volt) (3/99) Americas
114.10. E2.00-3.20XM MAST SPEEDS (72 or 80 Volt) Europe
114.11. E2.00-3.20XM MAST SPEEDS (72 or 80 Volt) Europe
114.12. E2.00-3.20XM, E2.00-3.20XM2, MAST SPEEDS (72 or 80 Volt) (3/99) Europe
114.13. J40-65XM MAST SPEEDS (36 or 48 Volt) Americas
114.14. J40-65XM, J40-65XM2, MAST SPEEDS (36 or 48 Volt) (3/99) Americas
114.15. J2.00-3.20XM MAST SPEEDS (72 or 80 Volt) Europe
114.16. J2.00-3.20XM MAST SPEEDS (72 or 80 Volt) (3/99) Europe
114.17. TORQUE SPECIFICATIONS
114.18. REFERENCE TABLE
115.
115.1. FIGURE 1. J2.00-3.200XM TRANSISTOR CONTROLLERS FOR TRACTION MOTOR AND HYDRAULIC PUMP MOTORS
115.2. FIGURE 2. E1.50-3.20XMS TRANSISTOR CONTROLLERS FOR TRACTION MOTOR AND HYDRAULIC PUMP MOTORS
115.3. FIGURE 3. SCHEMATIC DIAGRAM, TRANSISTOR CONTROLLERS FOR TRACTION MOTOR AND HYDRAULIC PUMP MOTORS
115.4. FIGURE 4. WIRING DIAGRAM, J2.00-3.20XM TRANSISTOR CONTROLLERS FOR TRACTION MOTOR AND HYDRAULIC PUMP MOTORS
115.5. FIGURE 5. WIRING DIAGRAM, J2.00-3.20XM TRANSISTOR CONTROLLER FOR TRACTION MOTOR, CONTACTOR CONTROLLER FOR HYDRAULIC PUMP
115.6. FIGURE 6. WIRING DIAGRAM, E1.50-3.20XMS TRANSISTOR CONTROLLERS FOR TRACTION MOTOR AND HYDRAULIC PUMP MOTORS
115.7. FIGURE 7. WIRING DIAGRAM, E1.50-3.20XMS TRANSISTOR CONTROLLER FOR TRACTION MOTOR, CONTACTOR CONTROL FOR HYDRAULIC PUMP
115.8. FIGURE 8. WIRE HARNESS, J2.00-3.20XM
115.9. FIGURE 9. POWER CABLES AND BATTERY CONNECTOR, J2.00-3.20XM
115.10. FIGURE 10. E1.50-3.20XM TRUCK WIRING
115.11. FIGURE 11. TRUCK POWER CABLES
115.12. FIGURE 12. TRUCK POWER CABLES
115.13. FIGURE 13. HYDRAULIC LINKAGE SWITCH AND CHASSIS WIRING DETAILS
115.14. FIGURE 14. WIRING SCHEMATIC FOR THE INSTRUMENT PANEL, E/J2.00-3.20XM
115.15. FIGURE 15. DISPLAY PANELS AND PLUG CONNECTIONS
115.16. FIGURE 16. CONFIGURATION OF THE EV-T100 MOTOR CONTROLLER MODULE
115.17. FIGURE 17. CONTROL CARD CONNECTIONS
115.18. FIGURE 18. TRUCK MANAGEMENT MODULE (TMM1)
115.19. FIGURE 19. WIRING SCHEMATIC, E2.00-3.20XM TRANSISTOR CONTROLLERS FOR TRACTION MOTOR AND HYDRAULIC PUMP MOTORS
115.20. FIGURE 20. DETAIL OF BATTERY CONNECTOR WITH 12 VOLT TAP
115.21. FIGURE 21. HYDRAULIC SCHEMATIC, E/J2.00-3.20XM E1.50-2.00XMS
115.22. FIGURE 22. WIRING DIAGRAM FOR LIGHTS

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