Hyster B210 (N30AH) Service Manual - Image 2

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Hyster B210 (N30AH) Service Manual

$30.00

Type Of Manual: Service Manual
Number of Pages: 722
Size: 34.8MB
Format: PDF

Category: Hyster Service Manual PDF

Model List:
- B210 (N30AH)

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. GENERAL
30. DESCRIPTION
31. BATTERY SPECIFICATIONS
32. REPAIRS
33. OVERHEAD GUARD
34. Removal
35. Installation
36. BATTERY RESTRAINT AND SEAT ASSEMBLY
37. COUNTERWEIGHT
38. Removal
39. Installation
40. TRACTION MOTOR
41. Removal
42. Installation
43. HYDRAULIC TANK
44. Inspection
45. Repairs, Small Leaks
46. Repairs, Large Leaks
47. Cleaning
48. Steam Method Of Cleaning
49. Chemical Solution Method Of Cleaning
50. Additional Preparations For Repair
51. PAINTING INSTRUCTIONS
52. LABEL PLACEMENT
53. INTRODUCTION
54. GENERAL
55. DESCRIPTION
56. OPERATION
57. Lift Section
58. Tilt Section
59. Relief Valve
60. SOLENOID VALVE FOR AUXILIARY FUNCTION
61. Operation
62. REPAIRS
63. MAIN CONTROL VALVE
64. Removal and Disassembly
65. Cleaning and Inspection
66. Assembly
67. Installation
68. SOLENOID VALVE FOR AUXILIARY FUNCTION
69. Removal and Disassembly
70. Assembly and Installation
71. CHECKS AND ADJUSTMENTS
72. PRESSURE RELIEF VALVES
73. Primary Relief Valve
74. Seconday Relief Valve
75. CONTROL LEVER ARRANGEMENT
76. TROUBLESHOOTING
77. SPECIFICATIONS
78. DC Motor Maintenance
79. Safety Precautions Maintenance and Repair
80. General
81. Brush and Commutator Inspection
82. Hydraulic Pump Motor and Traction Motor
83. Steering Pump Motor
84. Normal Commutator Surface
85. Commutator Problems
86. Brush Replacement
87. Stoning the Commutator
88. Motors Repair
89. Disassemble
90. Traction Motor and Hydraulic Pump Motor
91. Steering Pump Motor
92. Assemble
93. Traction Motor and Hydraulic Pump Motor
94. Steering Pump Motor
95. Brush Alignment, Traction and Hydraulic Motors
96. Tests for Damaged Field and Armature
97. Test for an Open Circuit in Armature
98. Test for Short Circuit in One Armature Winding
99. Test for Short Circuit to Armature Shaft
100. Test for Open Circuit in Field Coil
101. Test for Short Circuit in Field Coil
102. Test for Short Circuit between Field and Motor Case
103. Brush Holder Test
104. Troubleshooting
105. Table 1. Normal Commutator Surfaces
106. Table 2. Commutator Problems
107. Table 3. Brush Wear Replacement Guide
108.
108.1. INTRODUCTION
108.1.1. GENERAL
108.1.2. DESCRIPTION
108.2. REPAIRS
108.2.1. REMOVAL OF THE DRIVE AXLE
108.2.2. CLEANING
108.2.3. INSPECTION
108.2.4. ASSEMBLY
108.2.5. INSTALLATION OF THE DRIVE AXLE ASSEMBLY
108.3. TROUBLESHOOTING
108.4. TORQUE SPECIFICATIONS
109.
109.1. STEERING CONTROL UNIT
109.1.1. GENERAL
109.1.2. DESCRIPTION
109.1.3. DISASSEMBLY AND INSPECTION
109.1.4. ASSEMBLY
109.2. TROUBLESHOOTING
110.
110.1. INTRODUCTION
110.1.1. GENERAL
110.1.2. DESCRIPTION
110.2. REPAIRS
110.2.1. STEERING AXLE ASSEMBLY
110.2.2. WHEEL AND HUBS
110.2.3. SPINDLES, BEARINGS AND TIE RODS
110.2.4. STEERING CYLINDER
110.3. TORQUE SPECIFICATIONS
110.4. TROUBLESHOOTING
111.
111.1. INTRODUCTION
111.1.1. GENERAL
111.1.2. DESCRIPTION AND OPERATION
111.2. REPAIRS
111.2.1. MASTER CYLINDER
111.2.2. BRAKES, E/J1.25-1.75XL(E25-35XL)
111.2.3. BRAKES, E/J2.00-3.00XL (E/J40-60XL)
111.3. SEAT BRAKE
111.3.1. REPAIRS
111.4. SPECIFICATIONS
111.5. TROUBLESHOOTING
112.
112.1. HYDRAULIC SYSTEM
112.1.1. GENERAL
112.1.2. DESCRIPTION
112.1.3. OPERATION
112.2. REPAIRS
112.2.1. HYDRAULIC PUMP
112.3. CHECKS AND ADJUSTMENTS
112.3.1. MAIN CONTROL VALVE
112.3.2. STEERING RELIEF VALVE
112.4. TROUBLESHOOTING
112.5. SPECIFICATIONS
113.
114.
114.1. INTRODUCTION
114.1.1. GENERAL
114.2. DESCRIPTION
114.2.1. GENERAL
114.2.2. STEERING COLUMN GAUGES, METERS AND INDICATORS
114.2.3. LED DISPLAY PANEL
114.2.4. LX SERIES DISPLAY PANEL
114.2.5. ZX SERIES DISPLAY PANELS
114.3. CHECKS AND ADJUSTMENTS
114.3.1. GENERAL
114.4. REPLACEMENT
114.4.1. GENERAL
114.4.2. METER REPLACEMENT
114.4.3. SENDER REPLACEMENT
114.4.4. DISPLAY PANEL
114.4.5. DISPLAY PANELS FOR THE EV – 100/200ZX MOTOR CONTROLLERS, COLUMN MOUNT
114.4.6. DISPLAY PANELS FOR THE EV-100/200ZX MOTOR CONTROLLERS, DASH MOUNT
114.5. SPECIFICATIONS
114.6. TROUBLESHOOTING
115.
116.
117.
118.
119.
120.
120.1. INTRODUCTION
120.1.1. GENERAL
120.1.2. INDICATORS WITH METER MOVEMENT
120.1.3. BATTERY INDICATORS WITH LCD OR LED DISPLAYS
120.2. CHECKS AND ADJUSTMENTS
120.2.1. BATTERY INDICATORS WITHOUT LIFT INTERRUPT, EARLY MODELS
120.2.2. BATTERY INDICATORS WITH LIFT INTERRUPT, EARLY MODELS
120.2.3. BATTERY INDICATORS WITHOUT LIFT INTERRUPT, LATER MODELS
120.2.4. BATTERY INDICATORS WITH LIFT INTERRUPT, LATER MODELS
120.2.5. LED DISPLAY WITH LIFT INTERRUPT
120.2.6. CHECKING CURTIS 933-1 METER
120.2.7. ADJUSTMENT OF CURTIS 933-1 METER
120.2.8. ADJUSTMENT OF SEVCON POWERGAUGE
120.3. CURTIS DASH DISPLAY ASSEMBLY
120.3.1. Description/Features
120.3.2. Operation
120.3.3. Testing
120.4. REPAIRS
120.4.1. BATTERY INDICATORS
120.4.2. CONTROLLER FOR THE BATTERY INDICATOR
120.4.3. DISPLAY PANEL COMPONENTS
120.4.4. REPLACING SEM DISPLAY PANEL
120.4.5. SEM DISPLAY PANEL REMOVAL
121.
122.
122.1. INTRODUCTION
122.1.1. General
122.1.2. Upright Weldments
122.1.3. Carriages (N40-50EA Only)
122.1.4. Operator Platform (R30E/EA/EA-FS Only)
122.2. VISTA TWO-STAGE UPRIGHTS
122.2.1. Description
122.2.2. Operation
122.3. VISTA THREE-STAGE UPRIGHTS
122.3.1. Description
122.3.2. Operation
123.
123.1. INTRODUCTION
123.1.1. General
123.2. REPAIRS
123.2.1. Replacement (N40-50ER)
123.2.2. Replacement (R30E/EA/EA-FS)
123.2.3. Carriage Or Operator Platform
123.3. TWO-STAGE UPRIGHT
123.3.1. Removal
123.3.2. Disassembly
123.3.3. Cleaning And Inspection
123.3.4. Lift Cylinders
123.3.5. Assembly
123.3.6. Installation
123.4. THREE-STAGE UPRIGHT
123.4.1. Removal
123.4.2. Disassembly
123.4.3. Cleaning And Inspection
123.4.4. Lift Cylinders
123.4.5. Assembly
123.4.6. Installation
123.5. GENERAL PROCEDURES
123.5.1. Replacing Load Wheels
123.6. CHECKS AND ADJUSTMENTS
123.6.1. Checking For Leaks In The Lift System
123.6.2. Lift Chain Adjustments
123.6.3. Upright Adjustments
123.6.4. Carriage Or Operator Platform Adjustment
123.7. TROUBLESHOOTING
124.
124.1. INTRODUCTION
124.1.1. GENERAL
124.1.2. MAST WELDMENTS
124.1.3. CARRIAGES
124.2. VISTA TWO-STAGE MAST
124.2.1. DESCRIPTION
124.2.2. OPERATION
124.3. VISTA THREE-STAGE MAST
124.3.1. DESCRIPTION
124.3.2. OPERATION
125.
125.1. INTRODUCTION
125.1.1. GENERAL
125.1.2. DESCRIPTION
125.2. REPAIRS
125.2.1. MAIN CYLINDER – DISASSEMBLY
125.2.2. MAIN CYLINDER – ASSEMBLY
125.2.3. FREE-LIFT CYLINDER – DISASSEMBLY
125.2.4. FREE-LIFT CYLINDER – ASSEMBLY
125.3. TROUBLESHOOTING
126.
126.1. INTRODUCTION
126.1.1. General
126.2. SAFETY PROCEDURES
126.3. LOAD BACKREST EXTENSION, CARRIAGE, LOAD ROLLERS, SIDE ROLLERS AND FORKS
126.3.1. Load Backrest Extension – Removal And Installation
126.3.2. Carriage Assembly – Removal And Installation
126.3.3. Carriage Load Rollers – Removal And Installation
126.3.4. Side Rollers – Disassembly And Assembly
126.3.5. Fork Replacement
126.4. TWO-STAGE MAST ASSEMBLY
126.4.1. Two-Stage Mast Assembly – Removal
126.4.2. Cleaning And Inspection
126.4.3. Lift Cylinders – Removal And Installation
126.4.4. Inner Mast Assembly – Removal And Installation
126.4.5. Hoses – Replace
126.4.6. Hoses And Cable Sheaves – Replace
126.4.7. Two-Stage Lift Chains
126.4.8. Two-Stage Chain Sheave – Removal And Installation
126.4.9. Load Rollers And Wear Plugs – Removal And Installation
126.4.10. Two-Stage Mast Assembly – Installation
126.5. THREE-STAGE MAST ASSEMBLY
126.5.1. Three-Stage Mast Assembly – Removal
126.5.2. Cleaning And Inspection
126.5.3. Free-Lift Cylinder – Removal And Installation
126.5.4. Inner And Intermediate Mast Assemblies – Removal And Installation
126.5.5. Hoses – Replace
126.5.6. Hose And Cable Sheaves – Replace
126.5.7. Three-Stage Lift Chains – Removal And Installation
126.5.8. Three-Stage Chain Sheaves – Diassembly And Assembly
126.5.9. Load Rollers And Wear Plugs – Removal And Installation
126.5.10. Three-Stage Mast Assembly – Installation
126.6. CHECKS AND ADJUSTMENTS
126.6.1. Check The Operation Of The Mast
126.6.2. Check For Leaks In The Hydraulic System
126.6.3. Check Lift Chains
126.6.4. Mast Adjustments
126.6.5. Carriage Adjustments
127.
128.
128.1. INTRODUCTION
128.1.1. GENERAL
128.1.2. HOW TO MOVE A DISABLED LIFT TRUCK
128.1.3. HOW TO PUT A LIFT TRUCK ON BLOCKS
128.2. MAINTENANCE SCHEDULE
128.3. MAINTENANCE PROCEDURES EVERY 8 HOURS OR DAILY
128.3.1. HOW TO MAKE CHECKS WITH KEY SWITCH OFF
128.3.2. SAFETY LABELS
128.3.3. HOW TO MAKE CHECKS WITH THE KEY SWITCH ON
128.3.4. Steering System
128.4. EVERY 350 HOURS OR TWO MONTHS
128.4.1. HYDRAULIC TANK BREATHER
128.4.2. STEERING TIE RODS, E/J1.25-1.75XL (E25-35XL) and J2.00-3.00XL (J40-60XL)
128.4.3. DIFFERENTIAL AND SPEED REDUCER
128.4.4. WHEEL NUT TORQUES
128.4.5. STEERING AXLE SPINDLES, E/J2.00-3.00XL (E/J40-60XL) E3.50-5.50XL (E70-120XL)
128.4.6. LIFT CHAINS
128.4.7. BRAKE FLUID
128.4.8. OTHER LUBRICATION
128.4.9. SEAT BRAKE
128.4.10. ELECTRICAL INSPECTION
128.5. EVERY 2000 HOURS OR YEARLY
128.5.1. HYDRAULIC SYSTEM
128.5.2. DIFFERENTIAL AND SPEED REDUCER
128.5.3. SERVICE BRAKES
128.5.4. CONTACTORS
128.5.5. WHEEL BEARINGS
128.5.6. LIFT CHAINS
128.6. GENERAL PROCEDURES
128.6.1. HOW TO CHARGE THE BATTERY
128.6.2. HOW TO CHANGE THE BATTERY
128.6.3. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
128.6.4. CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM
128.6.5. LIFT CHAIN ADJUSTMENTS
128.6.6. HOW TO CHECK THE PMT CIRCUIT
128.6.7. WELDING REPAIRS
128.6.8. CHANGE THE OVERHEAD GUARD
128.7. WHEELS AND TIRES
128.7.1. GENERAL
128.7.2. SOLID RUBBER TIRES (PRESS-ON)
128.7.3. PNEUMATIC TIRES
128.7.4. Install The Wheels
128.7.5. SOLID RUBBER TIRES THAT LOOK LIKE PNEUMATIC TIRES
128.8. SPECIFICATIONS
128.9. REFERENCE TABLE
129.
129.1. BATTERY SPECIFICATIONS
129.2. WHEELS AND TIRES
129.3. HYDRAULIC SYSTEM
129.4. CAPACITIES
129.5. UPRIGHT SPEEDS E/J1.25-1.75XL (E25-35XL) (36-48 volt)
129.6. UPRIGHT SPEEDS E/J1.25-1.75XL (E25-35XL)(36-48 volt)
129.7. UPRIGHT SPEEDS E/J2.00-3.00XL (E/J40-60XL) (36-48 volt)
129.8. UPRIGHT SPEEDS E/J2.00-3.00XL (E/J40-60XL) (72-80 volt)
129.9. TORQUE SPECIFICATIONS
129.10. TORQUE SPECIFICATIONS
129.11. EV-100 MOTOR CONTROLLER ADJUSTMENTS (SCR CONTROL FOR HYDRAULIC PUMP)
129.12. CABLEFORM MARK XI MOTOR CONTROLLER
129.13. UPRIGHT SPEEDS J25-35B (24-36 volt)
130.
131.
132.

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