Hyster C210 (N30XMH) Service Manual

Description

• Model List:
  • C210 (N30XMH)

• 1. _2
• 1.1. INTRODUCTION
• 1.1.1. GENERAL
• 1.1.2. LEAD-ACID BATTERIES
• 1.1.3. SPECIFIC GRAVITY
• 1.1.4. THE CHEMICAL REACTION IN A CELL
• 1.2. ELECTRICAL TERMS
• 1.2.1. HOW TO SELECT THE BATTERY
• 1.2.2. VOLTAGE OF A BATTERY
• 1.2.3. THE BATTERY AS A COUNTERWEIGHT
• 1.2.4. BATTERY RATINGS
• 1.3. BATTERY MAINTENANCE
• 1.3.1. SAFETY PROCEDURES
• 1.3.2. MAINTENACE RECORDS
• 1.3.3. THE NEW BATTERY
• 1.3.4. HOW TO CLEAN THE BATTERY
• 1.3.5. HOW TO ADD WATER
• 1.3.6. THE HYDROMETER
• 1.3.7. BATTERY TEMPERATURE
• 1.3.8. CHARGING THE BATTERY
• 1.3.9. WHERE TO CHARGE THE BATTERIES
• 1.3.10. BATTERY CONNECTORS
• 1.3.11. BATTERY CARE
• 1.4. INTRODUCTION
• 1.4.1. GENERAL
• 1.4.2. DESCRIPTION
• 1.5. REPAIRS
• 1.5.1. OVERHEAD GUARD
• 1.5.2. BATTERY RESTRAINT AND SEAT ASSEMBLY
• 1.5.3. COUNTERWEIGHT
• 1.5.4. TRACTION MOTOR
• 1.5.5. HYDRAULIC TANK
• 1.5.6. PAINTING INSTRUCTIONS
• 1.5.7. LABEL REPLACEMENT
• 2. _2
• 2.1. DC Motor Maintenance
• 2.2. Safety Precautions Maintenance and Repair
• 2.3. General
• 2.4. Brush and Commutator Inspection
• 2.5. Hydraulic Pump Motor and Traction Motor
• 2.6. Steering Pump Motor
• 2.7. Normal Commutator Surface
• 2.8. Commutator Problems
• 2.9. Brush Replacement
• 2.10. Stoning the Commutator
• 2.11. Motors Repair
• 2.12. Disassemble
• 2.13. Traction Motor and Hydraulic Pump Motor
• 2.14. Steering Pump Motor
• 2.15. Assemble
• 2.16. Traction Motor and Hydraulic Pump Motor
• 2.17. Steering Pump Motor
• 2.18. Brush Alignment, Traction and Hydraulic Motors
• 2.19. Tests for Damaged Field and Armature
• 2.20. Test for an Open Circuit in Armature
• 2.21. Test for Short Circuit in One Armature Winding
• 2.22. Test for Short Circuit to Armature Shaft
• 2.23. Test for Open Circuit in Field Coil
• 2.24. Test for Short Circuit in Field Coil
• 2.25. Test for Short Circuit between Field and Motor Case
• 2.26. Brush Holder Test
• 2.27. Troubleshooting
• 2.28. Table 1. Normal Commutator Surfaces
• 2.29. Table 2. Commutator Problems
• 2.30. Table 3. Brush Wear Replacement Guide
• 3.
• 3.1. INTRODUCTION
• 3.1.1. GENERAL
• 3.1.2. DESCRIPTION
• 3.2. REPAIRS
• 3.2.1. REMOVAL OF THE DRIVE AXLE
• 3.2.2. CLEANING
• 3.2.3. INSPECTION
• 3.2.4. ASSEMBLY
• 3.2.5. INSTALLATION OF THE DRIVE AXLE ASSEMBLY
• 3.3. TROUBLESHOOTING
• 3.4. TORQUE SPECIFICATIONS
• 4.
• 4.1. INTRODUCTION
• 4.1.1. GENERAL
• 4.1.2. DESCRIPTION
• 4.2. REPAIRS
• 4.2.1. STEERING AXLE ASSEMBLY
• 4.2.2. SPINDLES, BEARINGS, AND TIE RODS
• 4.2.3. STEERING CYLINDER
• 4.3. TROUBLESHOOTING
• 4.4. TORQUE SPECIFICATIONS
• 5.
• 5.1. STEERING SYSTEM
• 5.1.1. GENERAL
• 5.1.2. DESCRIPTION
• 5.1.3. STEERING WHEEL AND COLUMN ASSEMBLY
• 5.2. POWER STEERING MOTOR AND PUMP
• 5.2.1. DESCRIPTION
• 5.2.2. REMOVAL AND DISASSEMBLY, E1.25-3.00XL (E25-60XL), J2.00-3.00XL (J40-60XL), E2.00-3.20XM (E45-65XM)
• 5.2.3. REMOVAL AND DISASSEMBLY, E3.50-5.50XL (E70-120XL, E70-120XL3)
• 5.2.4. REMOVAL AND DISASSEMBLY, J2.00-3.20XM (J40-65XM)
• 5.2.5. REMOVAL AND DISASSEMBLY, A1.00-1.50XL (A20-30XL)
• 5.2.6. REMOVAL AND DISASSEMBLY, E1.50-2.00XMS (E25-40XMS)
• 5.2.7. ASSEMBLY AND INSTALLATION All models with a verticle mount except the J2.00-3.20XM (J40-65M)
• 5.2.8. ASSEMBLY AND INSTALLATION, J2.00-3.20XM (J40-65XM)
• 5.2.9. ASSEMBLY AND INSTALLATION, E1.50-2.00XMS (E25-40XMS)
• 5.2.10. REPAIRS, POWER STEERING PUMP
• 5.3. HYDRAULIC STEERING MOTOR
• 5.3.1. DESCRIPTION
• 5.3.2. REPAIRS, HYDRAULIC STEERING MOTOR
• 5.4. CHECKS AND ADJUSTMENTS
• 5.4.1. AIR IN THE STEERING SYSTEM
• 5.4.2. CHECK STEERING PRESSURE
• 5.4.3. CHECK THE TENSION OF THE STEERING CHAIN (Units With MDU Only)
• 5.4.4. CHECK OPTIONAL ENCODER AND ACTIVATOR CIRCUITS
• 5.5. TROUBLESHOOTING
• 6.
• 6.1. INTRODUCTION
• 6.1.1. GENERAL
• 6.1.2. DESCRIPTION
• 6.1.3. OPERATION
• 6.2. REPAIRS
• 6.2.1. STEERING WHEEL AND COLUMN ASSEMBLY
• 6.3. CHECKS AND ADJUSTMENTS
• 6.3.1. REMOVE AIR FROM THE SYSTEM
• 6.4. TROUBLESHOOTING
• 7.
• 7.1. INTRODUCTION
• 7.1.1. GENERAL
• 7.1.2. DESCRIPTION AND OPERATION
• 7.2. REPAIRS
• 7.2.1. ELECTRIC BRAKE
• 7.2.2. BRAKE SWITCH
• 7.3. TROUBLESHOOTING
• 8.
• 8.1. INTRODUCTION
• 8.1.1. GENERAL
• 8.1.2. DESCRIPTION AND OPERATION
• 8.1.3. SERVICE BRAKES
• 8.1.4. PARKING BRAKE
• 8.1.5. MASTER CYLINDER
• 8.1.6. SEAT BRAKE ASSEMBLY
• 8.2. CHECKS AND ADJUSTMENTS
• 8.2.1. ADJUST THE SERVICE BRAKES
• 8.2.2. ADJUST THE BRAKE PEDAL
• 8.2.3. ADJUST THE MASTER CYLINDER
• 8.2.4. REMOVE THE AIR FROM THE BRAKE SYSTEM
• 8.2.5. TEST THE PARKING BRAKE NOT APPLIED WARNING
• 8.3. TROUBLESHOOTING
• 8.4. TORQUE SPECIFICATIONS
• 9.
• 9.1. INTRODUCTION
• 9.1.1. GENERAL
• 9.1.2. DESCRIPTION
• 9.1.3. OPERATION
• 9.2. REPAIRS
• 9.2.1. HYDRAULIC TANK
• 9.2.2. FILTER REPLACEMENT
• 9.2.3. HYDRAULIC PUMP
• 9.2.4. MAIN CONTROL VALVE
• 9.2.5. STEERING PUMP
• 9.2.6. ROTARY ACTUATOR VALVE
• 9.2.7. STEERING CONTROL UNIT
• 9.2.8. STEERING CYLINDER
• 9.3. CHECKS AND ADJUSTMENTS
• 9.3.1. MAIN CONTROL VALVE
• 9.3.2. STEERING RELIEF VALVE
• 9.4. TROUBLESHOOTING CHART
• 9.5. SPECIFICATIONS
• 10.
• 10.1. INTRODUCTION
• 10.1.1. GENERAL
• 10.1.2. DESCRIPTION
• 10.1.3. OPERATION
• 10.1.4. Lift Section (See FIGURE 3.)
• 10.1.5. Auxiliary Section
• 10.1.6. Relief Valve (See FIGURE 5.)
• 10.2. REPAIRS
• 10.2.1. MAIN CONTROL VALVE
• 10.2.2. Removal (See FIGURE 8. And FIGURE 9.)
• 10.2.3. Disassembly (See FIGURE 6.)
• 10.2.4. Cleaning And Inspection
• 10.2.5. Assembly (See FIGURE 6.)
• 10.2.6. Installation, (See FIGURE 7. And FIGURE 8.)
• 10.2.7. CONTROL LEVER LINKAGE
• 10.2.8. Removal (See FIGURE 9.)
• 10.2.9. Disassembly (See FIGURE 9.)
• 10.2.10. Assembly And Installation (See FIGURE 9.)
• 10.2.11. CONTROL VALVE LINKAGE
• 10.2.12. Removal And Disassembly (See FIGURE 10.)
• 10.2.13. Assembly And Installation (See FIGURE 10.)
• 10.3. CHECKS AND ADJUSTMENTS
• 10.3.1. PRESSURE RELIEF VALVES
• 10.3.2. Primary Relief Valve (See FIGURE 12.)
• 10.3.3. Secondary Relief Valve (See FIGURE 12.)
• 10.4. TROUBLESHOOTING
• 10.5. TROUBLESHOOTING
• 11.
• 12.
• 12.1. INTRODUCTION
• 12.1.1. GENERAL
• 12.2. DESCRIPTION
• 12.2.1. GENERAL
• 12.2.2. STEERING COLUMN GAUGES, METERS AND INDICATORS
• 12.2.3. LED DISPLAY PANEL
• 12.2.4. LX SERIES DISPLAY PANEL
• 12.2.5. ZX SERIES DISPLAY PANELS
• 12.3. CHECKS AND ADJUSTMENTS
• 12.3.1. GENERAL
• 12.4. REPLACEMENT
• 12.4.1. GENERAL
• 12.4.2. METER REPLACEMENT
• 12.4.3. SENDER REPLACEMENT
• 12.4.4. DISPLAY PANEL
• 12.4.5. DISPLAY PANELS FOR THE EV – 100/200ZX MOTOR CONTROLLERS, COLUMN MOUNT
• 12.4.6. DISPLAY PANELS FOR THE EV-100/200ZX MOTOR CONTROLLERS, DASH MOUNT
• 12.5. SPECIFICATIONS
• 12.6. TROUBLESHOOTING
• 13.
• 14.
• 14.1. Electrical System
• 14.2. Safety Precautions Maintenance and Repair
• 14.3. General
• 14.4. Description
• 14.5. ZX Series Display Panels
• 14.6. Display Panel
• 14.7. Basic Display Panels
• 14.8. Performance Display
• 14.9. Brush Wear Indicators
• 14.10. SEM Display Panels – Features
• 14.11. Descriptions of Common Features
• 14.12. Additional Features of Premium Display Panel
• 14.13. Descriptions of Additional Features
• 14.14. SEM Display Panel Indicators
• 14.15. All Indicator Symbols
• 14.16. Hourmeter Indicator Symbol
• 14.17. Wrench Indicator Symbol
• 14.18. Battery Indicator Symbol
• 14.19. Battery State-of-Charge (BDI)
• 14.20. Brake Fluid Too Low Symbol
• 14.21. Parking Brake Symbol
• 14.22. Fasten Seat Belt Symbol
• 14.23. LCD Screen (Standard Display Panel)
• 14.24. Additional Components of Premium Display Panel
• 14.25. Alpha Numerical Screen
• 14.26. STAR Push Button
• 14.27. Push Buttons 1 Through 5 – SEM
• 14.28. Other Control Components
• 14.29. Display Panel Components Replacement
• 14.30. ZX Panel Replacement
• 14.31. Display Panel Assembly
• 14.32. Key Switch, Replace
• 14.33. Indicator LEDs
• 14.34. Battery Indicators
• 14.35. Digital Display (Performance Display Panel Only)
• 14.36. Status Code or Performance Level Switches and Indicator LEDs (Pe
• 14.37. Basic Display Panel, Replace Parts
• 14.38. Performance Display Panel, Replace Parts
• 14.39. SEM Display Panel Replacement
• 14.40. Motor Controller (SR or SP) Replacement
• 14.41. Control Components Replacement
• 14.42. Start Switch, Replace
• 14.43. Brake Light Switch, Replace
• 14.44. Seat Switch, Replace
• 14.45. External Seat Switch, Adjust
• 14.46. Switch for Optional Seat Brake, Replace
• 14.47. Parking Brake Switch, Replace
• 14.48. Direction Switches (MONOTROL Pedal), Replace
• 14.49. Direction Control Switches (Steering Column), Replace
• 14.50. Direction Control Switches, E70-120XL 3 (Steering Column)
• 14.51. Brake Fluid Switch, Replace
• 14.52. Brush Wear and Overtemperature Sensors
• 14.53. Rocker Switches for Lights
• 14.54. Accelerator Position Sensor, Replace
• 14.55. On-Demand Steering Components
• 14.56. Lights, Converter, Relay, and Reverse Alarm
• 14.57. Brake, Tail, and Reverse Light Assembly, Replace
• 14.58. Flashing Light Assembly, Replace
• 14.59. Front, Rear Driving Light, or Spot Light Assemblies, Replace
• 14.60. Operator Compartment Light Assembly, Replace
• 14.61. Converter, Replace
• 14.62. Relay, Replace
• 14.63. Reverse Alarm, Replace
• 14.64. Horn and Horn Button
• 14.65. Horn Switch and Cover
• 14.66. Hydraulic Pump Switches
• 14.67. Control and Power Fuses Check
• 14.68. Brush Wear and Overtemperature Sensors Check – ZX
• 14.69. Thermal Sensors – SEM Check
• 14.70. Start Switch Adjustment
• 14.71. Accelerator Potentiometer and Start Switch E70-120XL, E70-120XL
• 14.72. E70-120XL
• 14.73. E70-120XL 3
• 14.74. Direction Switches (MONOTROL)
• 14.75. Brake Light Switch Adjustment
• 14.76. Seat Switch Check
• 14.77. Optional Seat Brake Switch Adjustment
• 14.78. Parking Brake Switch Adjustment
• 14.79. Direction Switches Check
• 14.80. Monotrol Pedal
• 14.81. Steering Column
• 14.82. Hydraulic Pump Switch Adjustment
• 14.83. MONOTROL or Accelerator Pedal Adjustment
• 14.84. Accelerator Position Sensor Adjustment
• 15.
• 16.
• 17.
• 17.1. INTRODUCTION
• 17.1.1. GENERAL
• 17.1.2. MAST WELDMENTS
• 17.1.3. CARRIAGES
• 17.2. VISTA TWO-STAGE MAST
• 17.2.1. DESCRIPTION
• 17.2.2. OPERATION
• 17.3. VISTA THREE-STAGE MAST
• 17.3.1. DESCRIPTION
• 17.3.2. OPERATION
• 18.
• 18.1. INTRODUCTION
• 18.1.1. GENERAL
• 18.1.2. DESCRIPTION
• 18.2. REPAIRS
• 18.2.1. MAIN CYLINDER – DISASSEMBLY
• 18.2.2. MAIN CYLINDER – ASSEMBLY
• 18.2.3. FREE-LIFT CYLINDER – DISASSEMBLY
• 18.2.4. FREE-LIFT CYLINDER – ASSEMBLY
• 18.3. TROUBLESHOOTING
• 19.
• 19.1. INTRODUCTION
• 19.1.1. General
• 19.2. SAFETY PROCEDURES
• 19.3. LOAD BACKREST EXTENSION, CARRIAGE, LOAD ROLLERS, SIDE ROLLERS AND FORKS
• 19.3.1. Load Backrest Extension – Removal And Installation
• 19.3.2. Carriage Assembly – Removal And Installation
• 19.3.3. Carriage Load Rollers – Removal And Installation
• 19.3.4. Side Rollers – Disassembly And Assembly
• 19.3.5. Fork Replacement
• 19.4. TWO-STAGE MAST ASSEMBLY
• 19.4.1. Two-Stage Mast Assembly – Removal
• 19.4.2. Cleaning And Inspection
• 19.4.3. Lift Cylinders – Removal And Installation
• 19.4.4. Inner Mast Assembly – Removal And Installation
• 19.4.5. Hoses – Replace
• 19.4.6. Hoses And Cable Sheaves – Replace
• 19.4.7. Two-Stage Lift Chains
• 19.4.8. Two-Stage Chain Sheave – Removal And Installation
• 19.4.9. Load Rollers And Wear Plugs – Removal And Installation
• 19.4.10. Two-Stage Mast Assembly – Installation
• 19.5. THREE-STAGE MAST ASSEMBLY
• 19.5.1. Three-Stage Mast Assembly – Removal
• 19.5.2. Cleaning And Inspection
• 19.5.3. Free-Lift Cylinder – Removal And Installation
• 19.5.4. Inner And Intermediate Mast Assemblies – Removal And Installation
• 19.5.5. Hoses – Replace
• 19.5.6. Hose And Cable Sheaves – Replace
• 19.5.7. Three-Stage Lift Chains – Removal And Installation
• 19.5.8. Three-Stage Chain Sheaves – Diassembly And Assembly
• 19.5.9. Load Rollers And Wear Plugs – Removal And Installation
• 19.5.10. Three-Stage Mast Assembly – Installation
• 19.6. CHECKS AND ADJUSTMENTS
• 19.6.1. Check The Operation Of The Mast
• 19.6.2. Check For Leaks In The Hydraulic System
• 19.6.3. Check Lift Chains
• 19.6.4. Mast Adjustments
• 19.6.5. Carriage Adjustments
• 20.
• 20.1. INTRODUCTION
• 20.1.1. GENERAL
• 20.1.2. DESCRIPTION
• 20.1.3. ATTACHMENT REMOVAL
• 20.1.4. DISASSEMBLY
• 20.1.5. ASSEMBLY
• 20.2. CHECKS AND ADJUSTMENTS
• 20.2.1. THRUST ROLLERS ON THE SIDE SHIFT CARRIAGE
• 20.2.2. THRUST ROLLERS ON THE BOOM
• 20.2.3. LOAD ROLLERS ON THE BOOM
• 20.2.4. TRAVERSE CHAIN ADJUSTMENT
• 20.3. TROUBLESHOOTING
• 20.3.1. SPECIFICATIONS