Hyster B210 (N30AH) Service Manual

Description

• 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.