Hyster C138 (N40-50EAER) Service Manual - Image 2

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Hyster C138 (N40-50EAER) Service Manual

$30.00

Type Of Manual: Service Manual
Number of Pages: 505
Size: 19.7MB
Format: PDF

Category: Hyster Service Manual PDF

Model List:
- C138 (N40-50EAER)

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.
130.
131.
132.
132.1. INTRODUCTION
132.1.1. GENERAL
132.2. ADJUSTMENTS
132.2.1. ADJUSTING THE CONTROL CARD FOR EV-100 (N40-50EA, N40-45ER Only)
132.3. ADJUSTING THE ACCELERATOR POTENTIOMETER
132.4. ADJUSTING THE HANDLEVER BRACKET
132.5. ADJUSTING THE LIFT SWITCH
132.6. ADJUSTING THE INTERLOCK SWITCH
132.7. ADJUSTING THE TILT SWITCH
133.
133.1. INTRODUCTION
133.1.1. GENERAL
133.1.2. INDICATORS WITH METER MOVEMENT
133.1.3. BATTERY INDICATORS WITH LCD OR LED DISPLAYS
133.2. CHECKS AND ADJUSTMENTS
133.2.1. BATTERY INDICATORS WITHOUT LIFT INTERRUPT, EARLY MODELS
133.2.2. BATTERY INDICATORS WITH LIFT INTERRUPT, EARLY MODELS
133.2.3. BATTERY INDICATORS WITHOUT LIFT INTERRUPT, LATER MODELS
133.2.4. BATTERY INDICATORS WITH LIFT INTERRUPT, LATER MODELS
133.2.5. LED DISPLAY WITH LIFT INTERRUPT
133.2.6. CHECKING CURTIS 933-1 METER
133.2.7. ADJUSTMENT OF CURTIS 933-1 METER
133.2.8. ADJUSTMENT OF SEVCON POWERGAUGE
133.3. CURTIS DASH DISPLAY ASSEMBLY
133.3.1. Description/Features
133.3.2. Operation
133.3.3. Testing
133.4. REPAIRS
133.4.1. BATTERY INDICATORS
133.4.2. CONTROLLER FOR THE BATTERY INDICATOR
133.4.3. DISPLAY PANEL COMPONENTS
133.4.4. REPLACING SEM DISPLAY PANEL
133.4.5. SEM DISPLAY PANEL REMOVAL
134.
135.
135.1. INTRODUCTION
135.1.1. General
135.1.2. Upright Weldments
135.1.3. Carriages (N40-50EA Only)
135.1.4. Operator Platform (R30E/EA/EA-FS Only)
135.2. VISTA TWO-STAGE UPRIGHTS
135.2.1. Description
135.2.2. Operation
135.3. VISTA THREE-STAGE UPRIGHTS
135.3.1. Description
135.3.2. Operation
136.
136.1. INTRODUCTION
136.1.1. General
136.2. REPAIRS
136.2.1. Replacement (N40-50ER)
136.2.2. Replacement (R30E/EA/EA-FS)
136.2.3. Carriage Or Operator Platform
136.3. TWO-STAGE UPRIGHT
136.3.1. Removal
136.3.2. Disassembly
136.3.3. Cleaning And Inspection
136.3.4. Lift Cylinders
136.3.5. Assembly
136.3.6. Installation
136.4. THREE-STAGE UPRIGHT
136.4.1. Removal
136.4.2. Disassembly
136.4.3. Cleaning And Inspection
136.4.4. Lift Cylinders
136.4.5. Assembly
136.4.6. Installation
136.5. GENERAL PROCEDURES
136.5.1. Replacing Load Wheels
136.6. CHECKS AND ADJUSTMENTS
136.6.1. Checking For Leaks In The Lift System
136.6.2. Lift Chain Adjustments
136.6.3. Upright Adjustments
136.6.4. Carriage Or Operator Platform Adjustment
136.7. TROUBLESHOOTING
137.
137.1. INTRODUCTION
137.1.1. GENERAL
137.2. REPAIRS
137.2.1. Replacement (30E/EA/EA- FS) (See FIGURE 2.)
137.2.2. OPERATOR PLATFORM
137.2.3. Removal
137.2.4. Installation
137.3. TWO-STAGE UPRIGHT
137.3.1. REMOVAL
137.3.2. DISASSEMBLY (See FIGURE 3., and FIGURE 4.)
137.3.3. CLEANING AND INSPECTION
137.3.4. LIFT CYLINDERS
137.3.5. ASSEMBLY
137.3.6. INSTALLATION
137.4. THREE-STAGE UPRIGHT
137.4.1. REMOVAL
137.4.2. DISASSEMBLY (See FIGURE 4., and FIGURE 6.)
137.4.3. CLEANING AND INSPECTION
137.4.4. LIFT CYLINDERS
137.4.5. ASSEMBLY (See FIGURE 4., and FIGURE 6.)
137.4.6. INSTALLATION
137.5. GENERAL PROCEDURESS
137.5.1. REPLACE THE LOAD WHEELS
137.6. CHECKS AND ADJUSYMENTS
137.6.1. CHECK FOR LEAKS IN THE LIFT SYSTEM
137.6.2. LIFT CHAIN ADJUSTMENT
137.6.3. UPRIGHT ADJUSTMENTS
137.6.4. OPERATOR PLATFORM ADJUSTMENT
137.7. TROUBLESHOOTING
137.8. VISTA UPRIGHT REPAIR
138.
138.1. INTRODUCTION
138.1.1. GENERAL
138.1.2. DESCRIPTION
138.1.3. OUTER FRAME
138.1.4. SCISSOR ARMS
138.1.5. INNER FRAME
138.1.6. SIDESHIFT FRAME
138.1.7. REACH CYLINDERS
138.1.8. TILT CYLINDER
138.1.9. SIDESHIFT CYLINDER
138.1.10. SELECTION VALVES
138.2. CHECKS AND ADJUSTMENTS
138.2.1. REMOVE AIR FROM THE HYDRAULIC SYSTEM
138.2.2. ADJUST THE STROKE OF THE REACH CYLINDERS
138.2.3. ADJUST THE STROKE OF THE TILT CYL-INDER
138.3. SPECIFICATIONS
138.4. TROUBLESHOOTING
139.
140.
140.1. INTRODUCTION
140.1.1. GENERAL
140.1.2. HOW TO MOVE A DISABLED LIFT TRUCK
140.1.3. HOW TO PUT A LIFT TRUCK ON BLOCKS
140.1.4. How to Raise the Load Wheels
140.2. MAINTENANCE SCHEDULE
140.3. MAINTENANCE PRODEDURES
140.4. EVERY 8 HOURS OR DAILY
140.4.1. CHECKS BEFORE OPERATION
140.4.2. Battery
140.4.3. CHECK THE OPERATION
140.5. EVERY 350 HOURS OR TWO MONTHS
140.5.1. DIRECTION AND SPEED CONTROL
140.5.2. BRAKE FLUID
140.5.3. HYDRAULIC TANK BREATHER
140.5.4. CONTACTORS
140.5.5. MOTOR BRUSHES
140.5.6. SAFETY LABELS
140.5.7. LIFT CHAINS
140.5.8. HINGES, LEVERS AND PEDALS
140.5.9. MASTER DRIVE UNIT
140.5.10. ARTICULATION STOPS, STEERING AXLE
140.6. EVERY 2000 HOURS OR YEARLY
140.6.1. MASTER DRIVE UNIT
140.6.2. STEERING CHAIN
140.6.3. STEERING AXLE ASSEMBLY
140.6.4. BRAKE ASSEMBLY
140.6.5. REPLACE THE HYDRAULIC OIL AND FILTER
140.6.6. LOAD WHEEL BEARINGS
140.7. GENERAL PROCEDURES
140.7.1. CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM
140.7.2. HOW TO CHARGE THE BATTERY
140.7.3. HOW TO CHANGE THE BATTERY
140.7.4. HOW TO ADJUST THE BRAKE
140.8. WHEELS AND TIRE
140.8.1. HOW TO CHANGE THE DRIVE TIRE AND STEERING TIRE
140.8.2. HOW TO REPLACE THE LOAD WHEELS
140.8.3. HOW TO REPLACE THE CASTER WHEELS
140.9. BATTERY SPECIFICATIONS
141.
142.
142.1. LIFT CAPACITIES
142.2. MASTER DRIVE UNIT
142.3. CAPACITIES
142.4. CONTROL SETTINGS N40-50EA/ER – Control Card Adjustments
142.5. CONTROL SETTINGS – N30FR, N40-50FA/FR
142.6. HYDRAULIC SYSTEM SPECIFICATIONS
142.7. BATTERY SPECIFICATIONS
142.8. REACH CARRIAGE SPECIFICATIONS

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