Hyster C138 (N40-50EAER) Service Manual

Description

• 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