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Hyster E210 (V30ZMD E2.00-3.20XM E45-65Z) Service Manual – PDF DOWNLOAD
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Description
Hyster E210 (V30ZMD E2.00-3.20XM E45-65Z) Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster E210 (V30ZMD E2.00-3.20XM E45-65Z) Service Manual – PDF DOWNLOAD
Language : English
Pages : 1008
Downloadable : Yes
File Type : PDF
Size: 58.7 MB
TABLE OF CONTENTS:
Hyster E210 (V30ZMD E2.00-3.20XM E45-65Z) Service Manual – PDF DOWNLOAD
AC Motor ControllersDisplay Panel....................................................... 1 toc................................................................................. 1 AC Motor Controllers/Display Panel.............................................. 1 Description..................................................................... 4 General..................................................................... 4 AC Motors............................................................... 4 Motor Controllers....................................................... 4 Master Controller....................................................... 4 Dash Display............................................................ 4 Controller Area Network Bus (CANbus).................................... 5 Master Controller Checks and Adjustments........................................ 5 Function Settings............................................................... 6 General..................................................................... 6 Function Numbers............................................................ 6 Function Descriptions........................................................... 8 General..................................................................... 8 Function Number 1 BATTERY VOLTAGE....................................... 8 Function Number 2 EXTENDED SHIFT........................................ 8 Function Number 3 ACCELERATION 1........................................ 9 Function Number 4 ACCELERATION 2........................................ 9 Function Number 5 TOP SPEED LIMIT....................................... 9 Function Number 6 REGEN BRAKING......................................... 9 Function Number 7 AUTO DECELERATION..................................... 9 Function Number 8 BDI ADJUSTMENT........................................ 9 Function Number 9 LIFT INTERRUPT........................................ 9 Function Number 10 POWER STEERING TIME DELAY............................ 10 Function Number 11 SERVICE REMINDER..................................... 10 Function Number 12 CUSTOM............................................... 10 Function Number 13 PUMP SPEED 1......................................... 10 Function Number 14 PUMP SPEED 2......................................... 10 Function Number 15 PUMP SPEED 3......................................... 10 Function Number 16 PUMP ACCELERATION.................................... 10 Troubleshooting................................................................. 11 General..................................................................... 11 Controller Status Light Emitting Diodes (LEDs).............................. 11 Master Controller....................................................... 12 AC Motor Controllers.................................................... 12 Status Codes................................................................ 18 AC Motor Controllers Status Code Charts......................................... 20 AC Transistor Motor Controller Replacement...................................... 40 General..................................................................... 40 General Maintenance Instructions............................................ 46 Special Precautions..................................................... 46 Fuses....................................................................... 47 Fan Test.................................................................... 47 Contactors.................................................................. 47 Repair.................................................................. 47 Thermal Sensors............................................................. 51 Motor Controller, Replace................................................... 51 Display Panel................................................................... 52 General..................................................................... 52 Premium Display Panel................................................... 52 Standard Display Panel.................................................. 52 Display Functions and Features.................................................. 53 Key-On Initialization....................................................... 53 Standard Display............................................................ 54 Premium Display............................................................. 54 Lift Truck Inspection Function.............................................. 55 Access to Service Functions................................................. 55 Service Functions........................................................... 55 Service Functions........................................................... 56 Performance Modes........................................................... 58 Battery Discharge Indicator (BDI)........................................... 58 Hourmeter................................................................... 59 Dash Display Service Menu Navigation............................................ 67 General..................................................................... 67 Moving Through Menu Selections.............................................. 67 Editing and Adding Information.............................................. 67 tables.............................................................................. 1 Table 1. Factory Parameters for J2.00-3.20XM (J40-65Z) (A416/B41................ 6 Table 2. Factory Setting for V30ZMD (D210/E210) and E2.00-3.20XM................ 6 Table 3. Factory Setting for E1.50-2.00XM (E25-35Z, E40ZS) (E114................ 7 Table 4. Factory Parameters for E3.50-5.50XL, E4.50XLS (E70-120Z................ 8 Table 5. List of Status Codes................................................... 18 Table 6. 42-Pin Connections/Descriptions for Master Controller.................. 49 Table 7. Pin Connections/Descriptions for 72/80 (Gen IV) Volt Mo................ 50 Table 8. Pin Connections/Descriptions for 36/48 and 72v/80v (Gen................ 51 AC Motor Repair......................................................................... 69 toc................................................................................. 69 AC Motor Repair................................................................. 69 General......................................................................... 71 AC Motor Repair................................................................. 71 Disassemble................................................................. 71 Assemble.................................................................... 76 Troubleshooting................................................................. 78 Brake System............................................................................ 80 toc................................................................................. 80 Brake System.................................................................... 80 General......................................................................... 83 Description and Operation....................................................... 83 Service Brakes.............................................................. 83 Master Cylinder............................................................. 84 Parking Brake............................................................... 85 Service Brakes Repair........................................................... 85 Remove and Disassemble...................................................... 85 Clean....................................................................... 89 Inspect..................................................................... 89 Assemble and Install........................................................ 89 Adjust...................................................................... 92 Parking Brake Repair............................................................ 94 Remove and Disassemble...................................................... 94 Assemble and Install........................................................ 94 Adjust...................................................................... 95 Master Cylinder Repair.......................................................... 99 Remove...................................................................... 99 Disassemble................................................................. 100 Clean and Inspect........................................................... 102 Assemble.................................................................... 102 Install..................................................................... 105 Seat Brake Assembly............................................................. 105 Seat Brake, Adjust - Lift Truck Models E2.00-3.20XM (E45-65XM, E............ 105 Brake Switch, Adjust - Lift Truck Models E2.00-3.20XM (E45-65XM,............ 105 Electric Seat Brake, Adjust for Lift Truck Model E2.00-3.20XM (E............ 106 Electric Seat Brake Adjustment With Handle For Lift truck Models............ 108 Remove.................................................................. 108 Clean................................................................... 108 Inspect................................................................. 108 Install................................................................. 110 Adjustments................................................................. 110 Solenoid Adjustment..................................................... 110 Traction cutoff Switch Adjustment....................................... 110 Cable Adjustment........................................................ 112 Service Brakes Adjustment....................................................... 114 Brake Pedal Adjustment.......................................................... 114 Master Cylinder Adjustment...................................................... 114 Brake System Air Removal........................................................ 114 Parking Brake Not Applied Switch Test........................................... 115 Torque Specifications........................................................... 115 Troubleshooting................................................................. 115 Capacities and Specifications........................................................... 120 toc................................................................................. 120 Capacities and Specifications................................................... 120 Counterweights.................................................................. 122 Hydraulic System................................................................ 122 Steering System................................................................. 123 Specifications.............................................................. 123 Turning Radius.............................................................. 123 Wheels and Tires................................................................ 124 Battery Specifications.......................................................... 125 E2.00-3.20XM (E45-65Z, V30ZMD).............................................. 125 Capacities...................................................................... 126 Drift Rates (Maximum) for Tilt Cylinders........................................ 126 Mast Speeds..................................................................... 127 E45-65Z (G108), and V30ZMD (D210/E210) Mast Speeds (36 or 48 Vol............ 127 E2.00-3.20XM Mast Speeds (72 or 80 Volt) Europe............................. 129 E2.00-3.20XM Mast Speeds (72 or 80 Volt) Europe............................. 131 Torque Specifications........................................................... 132 Frame....................................................................... 132 Drive Axle, Speed Reducer, and Differential E.200-3.20XM (E45-65............ 132 Steering Axle E2.00-3.20XM (E45-65Z and V30ZMD)............................. 133 Masts....................................................................... 133 Seat Brake.................................................................. 133 Hydraulic Pump and Fittings................................................. 133 Adhesives and Sealants.......................................................... 134 tables.............................................................................. 120 Table 1. Manual Hydraulic Control Valve......................................... 122 Table 2. E-Hydraulic Control Valve.............................................. 122 Cylinder Repair......................................................................... 136 toc................................................................................. 136 Cylinder Repair................................................................. 136 General......................................................................... 139 Description..................................................................... 139 Safety Procedures When Working Near Mast........................................ 140 Tilt Cylinder Repair............................................................ 142 Remove...................................................................... 142 Disassemble................................................................. 142 Inspect..................................................................... 143 Clean....................................................................... 143 Assemble.................................................................... 143 Install..................................................................... 146 Tilt Cylinders, Adjust...................................................... 146 Tilt Cylinder Leak Check.................................................... 148 Torque Specifications....................................................... 149 Piston Rod Nut.......................................................... 149 Gland................................................................... 149 Tilt Cylinder Mounting Capscrew......................................... 150 Tilt Cylinder Rod End Capscrew.......................................... 150 Lift Cylinder Repair............................................................ 150 Main Lift Cylinders......................................................... 150 Remove.................................................................. 150 Disassemble............................................................. 151 Clean................................................................... 152 Inspect................................................................. 152 Assemble................................................................ 152 Install................................................................. 153 Two-Stage FFL Left Side Main Lift Cylinder.................................. 154 Disassemble............................................................. 154 Clean................................................................... 156 Inspect................................................................. 156 Assemble................................................................ 156 Install................................................................. 156 Free-Lift Cylinder.......................................................... 156 Remove.................................................................. 156 Disassemble............................................................. 159 Clean................................................................... 160 Inspect................................................................. 160 Assemble................................................................ 160 Install................................................................. 161 Torque Specifications....................................................... 161 Lift Cylinders Leak Check................................................... 162 tables.............................................................................. 136 Table 1. Movement Rates (Maximum) for Tilt Cylinders............................ 149 DC Motor Maintenance.................................................................... 164 toc................................................................................. 164 DC Motor Maintenance............................................................ 164 General......................................................................... 166 Brush and Commutator Inspection................................................. 166 Hydraulic Pump Motor and Traction Motor..................................... 166 Steering Pump Motor......................................................... 169 Normal Commutator Surface................................................... 170 Commutator Problems......................................................... 170 Brush Replacement............................................................... 173 Stoning the Commutator.......................................................... 175 Motors Repair................................................................... 177 Disassemble................................................................. 177 Traction Motor and Hydraulic Pump Motor................................. 177 Steering Pump Motor..................................................... 179 Assemble.................................................................... 181 Traction Motor and Hydraulic Pump Motor................................. 181 Steering Pump Motor..................................................... 182 Brush Alignment, Traction and Hydraulic Motors.................................. 184 Tests for Damaged Field and Armature............................................ 184 Test for an Open Circuit in One Armature Winding............................ 184 Test for Short Circuit in One Armature Winding.............................. 185 Test for Short Circuit to Armature Shaft.................................... 185 Test for Open Circuit in Field Coil......................................... 185 Test for Short Circuit in Field Coil........................................ 186 Test for Short Circuit Between Field and Motor Case......................... 186 Brush Holder Test........................................................... 186 Troubleshooting................................................................. 186 tables.............................................................................. 164 Table 1. Normal Commutator Surfaces............................................. 169 Table 2. Commutator Problems.................................................... 170 Table 3. Brush Wear Replacement Guide........................................... 173 Drive Axle, Speed Reducer, and Differential............................................. 191 toc................................................................................. 191 Drive Axle, Speed Reducer, and Differential..................................... 191 General......................................................................... 193 Description..................................................................... 193 Drive Axle, Speed Reducer, and Differential Repair.............................. 196 Drive Axle, Remove.......................................................... 196 Drive Axle, Disassemble................................................. 197 Speed Reducer and Differential, Disassemble............................. 197 Clean....................................................................... 199 Inspect..................................................................... 199 Assemble.................................................................... 199 Speed Reducer and Differential, Assemble................................ 199 Input Gear Assembly, Install........................................ 199 New Pinion Assembly, Install........................................ 201 Drive Axle, Assemble.................................................... 207 Drive Axle Assembly, Install................................................ 208 Torque Specifications........................................................... 209 Wheel Nuts.................................................................. 209 Axle Shaft Capscrews........................................................ 209 Axle Hangers to Frame....................................................... 209 Back Plate to Axle Mount Capscrews.......................................... 209 Wheel Cylinder Capscrews.................................................... 209 Ring Gear to Differential Case.............................................. 209 Differential Case Halves.................................................... 209 Bearing Cap Capscrews....................................................... 209 Retainer Capscrews.......................................................... 210 Axle Housing to Differential Housing........................................ 210 Pinion Nut.................................................................. 210 Speed Reducer Housing to Differential Housing............................... 210 Traction Motor to Transmission.............................................. 210 Troubleshooting................................................................. 210 tables.............................................................................. 191 Table 1. Adjustment of Shims for Pinion Assembly................................ 201 Table 2. Ring and Pinion Tooth Contact Adjustment............................... 205 Electrical Diagrams..................................................................... 212 toc................................................................................. 212 Electrical Diagrams............................................................. 212 Electrical System (Trucks With AC Controllers).......................................... 289 toc................................................................................. 289 Electrical System (Trucks With AC Controllers).................................. 289 General......................................................................... 292 Description..................................................................... 293 Features of the Display Panels.............................................. 293 Other Control Components.................................................... 294 Display Panel and Key Switch Replacement........................................ 295 Display Panel, Replace...................................................... 295 Key Switch, Replace......................................................... 297 Controller Replacement.......................................................... 297 Traction and Pump Motor Controller Replacement.............................. 297 Master Controller, Replace.................................................. 303 Master Controller, Remove J2.00-3.20XM (J40-60Z) (A416/B416)............ 303 Master Controller, Install J2.00-3.20XM (J40-60Z) (A416/B416)........... 303 Master Controller, Remove E1.50-2.00XM (E25-35Z, E40ZS) (E114/F1........ 305 Master Controller, Install E1.50-2.00XM (E25-35Z, E40ZS) (E114/F........ 306 Master Controller, Remove E3.50-5.50XL E4.50XLS (E70-120Z,E100ZS........ 306 Master Controller, Install E3.50-5.50XL E4.50XLS (E70-120Z,E100Z........ 306 Control Components Replacement.................................................. 307 General..................................................................... 307 Start Switch, Replace....................................................... 307 Brake Light Switch, Replace................................................. 308 Seat Switch, Replace........................................................ 309 Parking Brake Switch, Replace............................................... 310 MONOTROL Pedal Direction Switches, Replace.................................. 312 Steering Column Direction Control Switches, Replace......................... 315 Remove.................................................................. 315 Install................................................................. 315 Brake Fluid Switch, Replace................................................. 317 Brush Wear and Over Temperature Sensors (DC Pump Motor Only)................ 317 Rocker Switches for Lights, Replace......................................... 317 Accelerator Position Sensor, Replace........................................ 318 On-Demand Steering Sensor, Replace.......................................... 319 Lights, Converter, Relay, and Reverse Alarm................................. 320 Brake, Tail, and Reverse Light Assembly, Replace........................ 320 Incandescent Assembly............................................... 320 LED Assembly - Remove............................................... 322 LED Assembly - Install.............................................. 324 Strobe Light Assembly, Replace.......................................... 325 Wire Harness Repair..................................................... 326 Del-City Crimp-Solder-Shrink Splice................................. 326 Front, Rear Driving Light or Spot Light Assemblies, Replace............. 328 Converter, Replace...................................................... 328 Remove, Lift Truck Models J2.00-3.20XM (J40-65Z) (A416/B416)........ 328 Install, Lift Truck Models J2.00-3.20XM (J40-65Z) (A416/B416)....... 330 Remove, Lift Truck Models E2.00-3.20XM (E45-65Z) (G108); V30ZMD .... 330 Install, Lift Truck Models E2.00-3.20XM (E45-65Z) (G108); V30ZMD.... 330 Remove, Lift Truck Models E3.50-5.50XL, E4.50XLS (E70-120Z, E100.... 332 Install, Lift Truck Models E3.50-5.50XL, E4.50XLS (E70-120Z, E10.... 332 Reverse Relay, Replace.................................................. 333 Lift Truck Models J2.00-3.20XM (J40-65Z) (A416/B416); V30ZMD (D2.... 333 Lift Truck Models E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D09.... 335 Backup Alarm, Replace................................................... 335 Horn and Horn Button, Replace............................................... 335 Horn Switch and Cover, Replace.......................................... 336 Hydraulic Pump Switches..................................................... 337 Fan Power Supply, Replace................................................... 337 Remove, Lift Truck Models E3.50-5.50XL (E70-120Z, E100ZS) (D098/........ 337 Install, Lift Truck Models E3.50-5.50XL (E70-120Z, E100ZS) (D098........ 337 Remove, Lift Truck Models J2.00-3.20XM (J40-65Z) (A416/B416)............ 337 Install, Lift Truck Models J2.00-3.20XM (J40-65Z) (A416/B416)........... 337 Remove, Lift Truck Models E2.00-3.20XM (E45-65Z) (G108)................. 339 Install, Lift Truck Models E2.00-3.20XM (E45-65Z) (G108)................ 340 Control and Power Fuse Check.................................................... 340 Fuse Locations.............................................................. 340 Brake Light Switch Adjustment................................................... 346 Seat Switch Check............................................................... 347 Seat Brake Adjustment........................................................... 347 Parking Brake Switch Adjustment................................................. 348 Direction Switches Check........................................................ 348 MONOTROL Pedal.............................................................. 348 Steering Column............................................................. 349 MONOTROL Pedal or Accelerator Pedal Adjustment.................................. 349 Accelerator Position Sensor Adjustment and Start Switch Adjustme................ 350 Acceleration Position Sensor, Adjust........................................ 350 Start Switch, Adjust........................................................ 352 tables.............................................................................. 289 Table 1. Wire Splice Size....................................................... 326 Electro-Hydraulic Control Valve......................................................... 355 toc................................................................................. 355 Electro-Hydraulic Control Valve................................................. 355 General......................................................................... 357 Description..................................................................... 357 Electro-Hydraulic Control System............................................ 357 Electro-Hydraulic Control Valve............................................. 360 Electro-Hydraulic Valve Driver Module....................................... 377 Mini-Lever Module (MLM)..................................................... 378 Joystick.................................................................... 379 Electro-Hydraulic Control Valve Repair.......................................... 379 Remove...................................................................... 379 Disassemble................................................................. 389 Solenoid Coil Replacement............................................... 391 Cartridge Replacement................................................... 395 Electro-Hydraulic Pressure Reducing Valve (EHPR) Replacement............ 396 Lift Circuit Check Valve Replacement.................................... 396 Compensator Cartridge Replacement....................................... 397 Primary and Secondary Relief Valves Replacement......................... 397 Tilt Counterbalance Valve Replacement................................... 397 Flow Regulator Valve Replacement........................................ 398 Assemble.................................................................... 398 Install..................................................................... 398 E-Hydraulics Calibration.................................................... 406 Mini-Lever Module............................................................... 408 Mini-Lever Module (MLM)..................................................... 408 Remove.................................................................. 408 Install................................................................. 408 Mini-Lever Replacement...................................................... 408 Remove.................................................................. 408 Clean and Inspect....................................................... 409 Install................................................................. 409 Push Button Switch Replacement.............................................. 410 Remove.................................................................. 410 Install................................................................. 411 Test........................................................................ 412 Mini-levers............................................................. 412 Full Stroke Test........................................................ 412 Function Returns to Neutral Test........................................ 412 Push Button Switch...................................................... 413 Joystick.................................................................... 413 Remove and Disassemble.................................................. 413 Inspect................................................................. 413 Assemble and Install.................................................... 413 Troubleshooting................................................................. 414 tables.............................................................................. 355 Table 1. Primary and Secondary Relief Valve Values.............................. 363 Table 2. Solenoid Resistance Values............................................. 391 Table 3. Cartridge and Solenoid Coil Nut Torque for Lift truck M................ 395 Table 4. Cartridge and Solenoid Coil Nut Torque for Lift truck M................ 396 Frame................................................................................... 428 toc................................................................................. 428 Frame........................................................................... 428 General......................................................................... 430 Description..................................................................... 430 Main Frame.................................................................. 430 Other Frame Weldments....................................................... 433 Overhead Guard.............................................................. 433 Overhead Guard Replacement...................................................... 434 Remove...................................................................... 434 Install..................................................................... 434 Battery and Operator Restraint System, Hood and Seat Brake, and ................ 441 Battery Restraint System.................................................... 441 Hood........................................................................ 442 Hood With E-Hydraulics...................................................... 443 Seat Brake.................................................................. 444 Operator Restraint System and Seat Assembly................................. 444 Automatic Locking Retractor (ALR)....................................... 444 Emergency Locking Retractor (ELR)....................................... 445 Counterweight Replacement....................................................... 446 Remove...................................................................... 447 Install..................................................................... 448 Traction Motor Replacement...................................................... 449 Remove...................................................................... 449 Install..................................................................... 451 Hydraulic Tank Repair........................................................... 451 Inspect..................................................................... 451 Clean....................................................................... 452 Steam Method............................................................ 452 Chemical Solution....................................................... 453 Additional Preparations for Repair.......................................... 453 Small Leaks, Repair......................................................... 453 Large Leaks, Repair......................................................... 454 Preparations for Usage After Repair......................................... 454 Painting Instructions........................................................... 454 Safety Label Replacement........................................................ 455 Battery Specifications.......................................................... 459 tables.............................................................................. 428 Table 1. Counterweights......................................................... 447 Table 2. Lift Truck Models E2.00-3.20XM (E45-65XM, E45-65XM 2 ) ................ 459 Table 3. Lift Truck Models E2.00-3.20XM (E40-65Z) (G108)........................ 460 Hydraulic System........................................................................ 463 toc................................................................................. 463 Hydraulic System................................................................ 463 General......................................................................... 467 Description..................................................................... 468 Hydraulic System............................................................ 468 Operation....................................................................... 478 Hydraulic System............................................................ 478 Hydraulic Gear Pump......................................................... 489 Rotator Actuator Valve...................................................... 489 Steering Pump............................................................... 491 Hydraulic Tank Repair........................................................... 499 Tank, Remove [E1.50-3.20XM (E25-65XM, E25-65XM 2 ) (D114, F108);............ 499 Tank, Remove [J2.00-3.20XM (J40-60XM, J40-60XM 2 ) (A216) and J2............ 501 Tank, Remove [J2.00-3.20XM (J40-60Z) (B416)]................................ 502 Hyraulic Tank [E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E............ 502 Inspect..................................................................... 503 Small Leaks, Repair......................................................... 504 Large Leaks, Repair......................................................... 504 Clean....................................................................... 504 Steam Method............................................................ 504 Chemical Solution Method................................................ 505 Additional Methods for Tank Repair.......................................... 505 Tank, Install [E1.50-3.20XM (E25-65XM, E25-65XM 2 ), (D114, F108............ 505 Tank, Install [J2.00-3.20XM (J40-60XM, J40-60XM 2 ) (A216) and J............ 506 Tank, Install [J2.00-3.20XM (J40-65Z) (B416)]............................... 506 Filter Replacement.............................................................. 507 All Lift Trucks Except [E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS............ 507 Remove.................................................................. 507 Install................................................................. 508 Lift Truck Models [E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D0............ 508 Remove.................................................................. 508 Install................................................................. 508 Lift truck Models [E2.00-3.20XM (E45-65Z) (G108) and E1.50-2.00X............ 509 Remove.................................................................. 509 Install................................................................. 511 Lift Truck Models [J2.00-3.20XM (J40-65Z) (B416)]........................... 511 Remove.................................................................. 511 Install................................................................. 513 Hydraulic Pump Repair........................................................... 514 Hydraulic Pump, Remove [E1.50-3.20XM (E25-65XM, E25-65XM 2 ) (D1............ 514 Hydraulic Pump, Disassemble E1.50-3.20XM (E25-65XM, E25-65XM 2 )............ 515 Inspect..................................................................... 516 Clean....................................................................... 516 Pump Seal Replace and Pump Assemble......................................... 516 Assemble Pump on Motor...................................................... 516 Hydraulic Pump and Motor, Install [E1.50-3.20XM (E25-65XM, E25-6............ 518 Hydraulic Pump, Remove [J2.00-3.20XM (J40-60XM, J40-60XM 2 ) (A2............ 519 Hydraulic Pump, Disassemble [E3.50-5.50XL, E4.50XLS (E70-120Z, E............ 520 Hydraulic Pump, Inspect [E3.50-5.50XL, E4.50XLS (E70-120Z, E100Z............ 522 Hydraulic Pump, Clean [E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)............ 522 Hydraulic Pump, Assemble [E3.50-5.50XL, E4.50XLS (E70-120Z, E100............ 522 Hydraulic Pump and Motor, Install [J2.00-3.20XM (J40-60XM, J40-6............ 522 Main Control Valve Repair....................................................... 524 Steering Pump Repair............................................................ 525 Pump, Remove and Disassemble [E1.50-3.20XM (E25-65XM, E25-65XM 2............ 525 Pump, Remove and Disassemble [J2.00-3.20XM (J40-60XM, J40-60XM 2............ 526 Pump, Assemble and Install.................................................. 528 Rotary Actuator Valve Repair.................................................... 529 Disassemble, Clean, and Inspect............................................. 529 Assemble.................................................................... 529 Steering Control Unit Replacement............................................... 530 Remove...................................................................... 530 Install..................................................................... 531 Steering Cylinder Repair........................................................ 537 Main Control Valve Check and Adjust............................................. 537 Steering Relief Valve Check and Adjust.......................................... 538 Specifications.................................................................. 539 Relief Valve Pressures*..................................................... 539 Hydraulic Tank Capacity (dipstick full mark)................................ 539 Hydraulic Pump Capacities - All Models Except E3.50-5.50XL, E4.5............ 539 Hydraulic Pump Capacities - Models E3.50-5.50XL, E4.50XLS (E70-1............ 539 Troubleshooting................................................................. 540 Steering.................................................................... 540 Steering Housing and Steering Control Unit.................................. 541 Hydraulic System............................................................ 542 Industrial Battery...................................................................... 546 toc................................................................................. 546 Industrial Battery.............................................................. 546 General......................................................................... 548 Lead-Acid Batteries............................................................. 548 Specific Gravity................................................................ 549 Chemical Reaction in a Cell..................................................... 549 Electrical Terms................................................................ 550 Battery Selection............................................................... 551 Battery Voltage................................................................. 552 Battery as a Counterweight...................................................... 552 Battery Ratings................................................................. 553 Kilowatt-Hours.............................................................. 553 Battery Maintenance............................................................. 553 Safety Procedures........................................................... 553 Maintenance Records......................................................... 554 New Battery................................................................. 554 Cleaning Battery............................................................ 554 Adding Water to Battery..................................................... 556 Hydrometer.................................................................. 557 Battery Temperature......................................................... 557 Charging Battery............................................................ 558 Types of Battery Charges................................................ 559 Methods of Charging..................................................... 560 Troubleshooting Charger................................................. 561 Knowing When Battery Is Fully Charged................................... 561 Where to Charge Batteries................................................... 561 Equipment Needed........................................................ 561 Battery Connectors.......................................................... 562 Battery Care................................................................ 562 tables.............................................................................. 546 Table 1. Battery Capacity Terms................................................. 553 Mast (2)................................................................................ 565 toc................................................................................. 565 Mast............................................................................ 565 General......................................................................... 568 Safety Procedures When Working Near Mast........................................ 568 Forks Repair.................................................................... 570 Remove...................................................................... 570 Install..................................................................... 571 Carriages Repair................................................................ 571 Standard Carriage, Remove................................................... 571 Hang-On Sideshift Carriage, Remove.......................................... 572 Standard Carriage and Hang-On Sideshift Carriage, Repair.................... 573 Standard Carriage, Install.................................................. 573 Hang-On Sideshift Carriage, Install......................................... 574 Integral Sideshift Carriage................................................. 574 Remove.................................................................. 574 Clean and Inspect....................................................... 576 Repair.................................................................. 576 Install................................................................. 577 Mast Repair..................................................................... 577 Remove...................................................................... 577 Two-Stage LFL and Two-Stage FFL Masts, Disassemble.......................... 579 Three-Stage FFL Mast........................................................ 586 Disassemble............................................................. 586 Mast and Chains, Clean and Inspect...................................... 589 Two-Stage LFL and Two-Stage FFL Mast, Assemble.............................. 590 Three-Stage FFL Mast, Assemble.............................................. 591 Install..................................................................... 593 Lift Cylinders Repair........................................................... 594 Main Lift Cylinders, Remove................................................. 594 Free-Lift Cylinder, Remove.................................................. 594 Lift Cylinders, Disassemble................................................. 595 Lift Cylinders, Assemble.................................................... 595 Main Lift Cylinders, Install................................................ 598 Free-Lift Cylinder, Install................................................. 599 Header Hose Arrangements........................................................ 599 Two-Stage LFL Mast, New Hose Install........................................ 599 Two-Stage LFL Mast, Adjust Hoses After Installation......................... 605 Two-Stage FFL Mast, New Hose Install........................................ 605 Two-Stage FFL Mast, Adjust Hoses After Installation......................... 610 Three-Stage FFL Mast, New Hose Install...................................... 612 Three-Stage FFL Mast, Adjust Hoses After Installation....................... 622 Header Hose Arrangement......................................................... 623 Two-Stage LFL Mast, New Hose Install........................................ 623 Two-Stage LFL Mast, Adjust Hoses After Installation......................... 623 Two-Stage FFL Mast, New Hose Install........................................ 627 Two-Stage FFL Mast, Adjust Hoses After Installation......................... 632 Three-Stage FFL Mast, New Hose Install...................................... 634 Three-Stage FFL Mast, Adjust Hoses After Install............................ 639 Lift and Tilt System Leak Check................................................. 643 Lift Cylinders Leak Check................................................... 643 Tilt Cylinders Leak Check................................................... 643 Tilt Cylinders Adjustment....................................................... 644 Lift Chains Adjustment.......................................................... 645 Mast Adjustment................................................................. 647 Carriage Adjustment............................................................. 649 Troubleshooting................................................................. 649 tables.............................................................................. 565 Table 1. Hook-Type Carriage Chain Adjustment.................................... 646 Table 2. Pin-Type Carriage Chain Adjustment..................................... 646 Mast Repairs............................................................................ 653 toc................................................................................. 653 Mast Repairs.................................................................... 653 General......................................................................... 656 Safety Procedures When Working Near Mast........................................ 656 Fork Repair..................................................................... 658 Remove...................................................................... 658 Install..................................................................... 658 Checks...................................................................... 659 Carriages Repair................................................................ 660 Standard Carriage........................................................... 660 Remove.................................................................. 660 Repair.................................................................. 661 Install................................................................. 661 Integral Sideshift Carriage................................................. 661 Remove.................................................................. 661 Clean and Inspect....................................................... 664 Repair.................................................................. 665 Install................................................................. 666 Mast Repair..................................................................... 666 Mast, Remove................................................................ 666 Two-Stage LFL and Two-Stage FFL Masts, Disassemble.......................... 670 Clean and Inspect........................................................... 676 Three-Stage FFL Mast........................................................ 677 Disassemble............................................................. 677 Clean and Inspect....................................................... 681 Two-Stage LFL and Two-Stage FFL Mast, Assemble.............................. 682 Three-Stage FFL Mast, Assemble.............................................. 683 Four-Stage FFL, Disassemble................................................. 685 Clean and Inspect........................................................... 689 Four-Stage FFL, Assemble.................................................... 691 Mast, Install............................................................... 693 Header Hose Arrangement......................................................... 696 Two-Stage LFL............................................................... 696 Two-Stage FFL............................................................... 703 Three-Stage FFL............................................................. 715 Four-Stage FFL.............................................................. 730 Adjustment.................................................................. 738 Lift Chains Adjustment.......................................................... 739 Carriage Adjustments............................................................ 741 Tilt Cylinders Adjustment....................................................... 741 Mast Adjustments................................................................ 745 Load Roller Adjustment...................................................... 745 Mast Side Kicking Adjustment................................................ 747 tables.............................................................................. 653 Table 1. Fork Tip Alignment..................................................... 659 Table 2. Pneumatic Tire Trucks.................................................. 699 Table 3. Cushion Tire Trucks.................................................... 699 Table 4. Standard Two-Stage Hose Dimensions..................................... 702 Table 5. Pneumatic Tire Trucks.................................................. 706 Table 6. Cushion Tire Trucks.................................................... 706 Table 7. Pneumatic Tire Trucks.................................................. 724 Table 8. Cushion Tire Trucks.................................................... 724 Table 9. Standard Three-Stage Hose Dimensions................................... 726 Table 10. Standard Four-Stage Hose Dimensions................................... 731 Table 11. Hook-Type Carriage Chain Adjustment................................... 739 Table 12. Pin-Type Carriage Chain Adjustment.................................... 740 Mast.................................................................................... 749 toc................................................................................. 749 Mast............................................................................ 749 General......................................................................... 751 Description and Operation....................................................... 751 Carriages................................................................... 751 Mast Mounts................................................................. 753 Two-Stage Mast, Limited Free-Lift (LFL)......................................... 755 Description and Operation................................................... 755 Two-Stage Mast, Full Free-Lift (FFL)............................................ 757 Description and Operation................................................... 757 Three-Stage Mast, Full Free-Lift (FFL).......................................... 759 Description and Operation................................................... 759 Four-Stage Mast................................................................. 762 Description and Operation................................................... 762 Cylinder Cushion During Lifting Sequence........................................ 765 Cylinder Cushion During Lowering Sequence....................................... 766 Metric and Inch (SAE) Fasteners......................................................... 768 toc................................................................................. 768 Metric and Inch (SAE) Fasteners................................................. 768 General......................................................................... 770 Threaded Fasteners.......................................................... 770 Nomenclature, Threads....................................................... 770 Strength Identification..................................................... 771 Cotter (Split) Pins......................................................... 771 Fastener Torque Tables...................................................... 776 Conversion Table............................................................ 778 tables.............................................................................. 768 Table 1. Bolts and Screws....................................................... 772 Table 2. Studs and Nuts......................................................... 773 Table 3. Torque Nuts............................................................ 774 Table 4. Torque Nuts With Nylon Insert.......................................... 775 Table 5. Torque Values for Metric Fasteners*.................................... 776 Table 6. Torque Values for Inch Fasteners*...................................... 777 Table 7. Conversion Table for Metric and English Units.......................... 778 Table 8. Cotter Pin Dimensional Data............................................ 779 Table 9. Cotter Pin Dimensional Data............................................ 780 Table 10. Cotter Pin Dimensional Data........................................... 781 Table 11. Cotter Pin Dimensional Data........................................... 783 Periodic Maintenance.................................................................... 787 toc................................................................................. 787 Periodic Maintenance............................................................ 787 General......................................................................... 791 Serial Number Data.......................................................... 791 How to Move Disabled Lift Truck............................................. 791 How to Tow Lift Truck................................................... 791 How to Put Lift Truck on Blocks............................................. 792 How to Raise Drive Tires................................................ 792 How to Raise Steering Tires............................................. 792 Maintenance Schedule............................................................ 793 Maintenance Procedures Every 8 Hours or Daily................................... 803 How to Make Checks With Key OFF............................................. 803 Tires and Wheels........................................................ 803 Forks................................................................... 804 Inspect............................................................. 804 Mast, Carriage, Lift Chains, Header Hoses, and Traverse Chains, ........ 805 Safety Labels........................................................... 806 Steering Column Latch................................................... 806 Operator Restraint System............................................... 806 Automatic Locking Retractor (ALR)................................... 806 Emergency Locking Retractor (ELR)................................... 806 Battery Restraint System V30ZMD (D210/E210); E1.50-2.00XM (E25-3........ 807 Battery Restraint System J2.00-3.20XM (J40-65Z) (A416) Lift Truc........ 808 Battery................................................................. 809 Attachment.............................................................. 809 Hydraulic System........................................................ 809 How to Make Checks With Key ON.............................................. 810 Horn, Lights, and Alarm................................................. 810 Steering System......................................................... 810 Service Brakes.......................................................... 811 Parking Brake........................................................... 811 Control Levers and Pedals............................................... 811 Direction and Speed Control Pedals...................................... 811 Lift System Operation................................................... 811 Oil Leaks............................................................... 812 First Service After First 100 Hours of Operation................................ 812 Change Filter for Hydraulic Oil............................................. 812 Maintenance Procedures Every 250 Hours or 6 Weeks............................... 813 Steering King Pins E1.50-2.00XM (E114/F114) Trucks Only..................... 813 Steering Tie Rods and Spindles.............................................. 813 Attachment Load Rollers, Lubricate.......................................... 814 Attachment Main Load Bearings and Roller Bearings........................... 814 Attachment Track Assembly................................................... 814 Traverse Chain Adjustment................................................... 814 Pivot Boom Chain Tension Check.............................................. 815 Attachment Hydraulic Hoses.................................................. 815 Maintenance Procedures Every 500 Hours or 3 Months.............................. 817 Differential and Speed Reducer V30ZMD (D210/E210); E2.00-3.20XM ............ 817 Wheel Nut Torques........................................................... 818 Header Hose Checks.......................................................... 818 Mast Lubrication............................................................ 818 Forks....................................................................... 822 Remove.................................................................. 822 Inspect................................................................. 823 Install................................................................. 823 Adjust.................................................................. 823 Brake Fluid V30ZMD (D210/E210); E1.50-2.00XM (E25-35Z, E40ZS) (E............ 824 Parking Brake Adjustment.................................................... 824 Seat Brake Operations Check................................................. 824 Maintenance Procedures Every 1000 Hours or 6 Months............................. 824 Lift Chains................................................................. 824 Wear Check.............................................................. 824 Lift Chain Lubrication...................................................... 825 Forks....................................................................... 825 Check Upper and Lower Bearings, Integral Sideshift Carriage................. 825 Steering King Pins E2.00-3.20XM (E45-65Z) (G108) and V30ZMD (D21............ 826 Steering Tie Rods J2.00-3.20XM (J40-65Z) (A416) Lift Truck Model............ 826 Steering Axle Spindles...................................................... 827 King Pins J2.00-3.20XM (J40-65Z) (A416)................................. 827 Hydraulic Tank Breather..................................................... 827 J2.00-3.20XM (J40-65Z) (A416)........................................... 827 E2.00-3.20XM (E45-E65Z) (G108) and V30XMD (D210/E210)................... 827 E1.50-2.00XM (E25-E35Z, E40ZS) (E114/F114).............................. 827 Differential and Speed Reducer J2.00-3.20XM (J40-65Z) (A416)................ 827 Brake Fluid J2.00-3.20XM (J40-65Z) (A416) Lift Truck Models................. 828 Attachment Main Load Bearings............................................... 829 Traverse Chain.............................................................. 829 Attachment Pivot Boom Chain................................................. 830 Pivot Boom Shaft Fitting, Lubricate......................................... 832 Attachment Moving Parts and Structural Assemblies........................... 832 Other Lubrication........................................................... 832 Electrical Inspection....................................................... 832 Contactors.............................................................. 832 Motor Brushes (DC Pump)................................................. 832 Motor Brushes, General.............................................. 832 Maintenance Procedures Every 2000 Hours or Yearly............................... 836 Hydraulic System............................................................ 836 Change Filter for Hydraulic Oil......................................... 836 Change Hydraulic Oil.................................................... 837 Differential and Speed Reducer.............................................. 837 Brake Fluid Replacement..................................................... 837 Service Brakes.............................................................. 838 Steering Tie Rods and Spindle Lift Truck Models E25-35Z, E40ZS (............ 838 Wheel Bearings.............................................................. 839 Steer Wheels, Lubrication............................................... 839 Drive Wheels, Lubrication............................................... 839 Lift Chains................................................................. 839 Forks....................................................................... 839 Replace Upper and Lower Bearings, Integral Sideshift Carriage............... 839 Limited Switch Roller Shafts, Traverse Attachment........................... 839 Attachment Roller Bearings.................................................. 839 Traverse Chain.............................................................. 839 Pivot Boom Assembly......................................................... 839 Other Lubrication........................................................... 839 Battery Maintenance............................................................. 840 How to Charge Battery....................................................... 840 How to Change Battery for J2.00-3.20XM (A416) and E2.00-3.20XM (............ 841 General................................................................. 841 How to Change Battery for V30ZMD (D210/E210); E1.50-2.00XM (E25-............ 843 General................................................................. 843 Lift and Tilt System Leak Check................................................. 846 Lift Cylinders Leak Check................................................... 846 Tilt Cylinders Leak Check................................................... 847 Safety Procedures When Working Near Mast........................................ 847 WHEN WORKING NEAR THE MAST ALWAYS:.......................................... 847 Lift Chain Adjustments.......................................................... 850 Welding Repairs................................................................. 851 Overhead Guard Changes.......................................................... 851 Wheels and Tire Maintenance..................................................... 852 Solid Rubber Tires V30ZMD (D210/E210); E1.50-2.00XM (E25-35Z, E4............ 852 Remove Wheels From Lift Truck........................................... 852 Remove and Install Tire on Wheel........................................ 852 Pneumatic Tires and Wheels J2.00-3.20XM (J40-65Z) (A416).................... 853 Remove Wheels From Lift Truck........................................... 853 Remove Wheel From Pneumatic Tire........................................ 854 Install Three- or Four-Piece Wheel in Pneumatic Tire.................... 855 Add Air to Tires........................................................ 856 Wheels, Install......................................................... 857 Solid Rubber Tires on Pneumatic Wheels...................................... 857 Remove Wheels From Lift Truck........................................... 857 Remove Solid Rubber Tire From Pneumatic Wheel........................... 858 Install Solid Rubber Tire on Pneumatic Wheel............................ 859 Wheels, Install......................................................... 860 Snap-On Tire, Change........................................................ 861 Remove Snap-On Solid Tire From Wheel.................................... 861 Install Snap-On Solid Tire on Wheel..................................... 862 Adhesives and Sealants.......................................................... 863 tables.............................................................................. 787 Table 1. Maintenance Schedule................................................... 796 Steering Axle........................................................................... 866 toc................................................................................. 866 Steering Axle................................................................... 866 General......................................................................... 868 Description..................................................................... 868 Steering Axle Assembly Replacement.............................................. 870 Remove...................................................................... 870 Install..................................................................... 870 Wheels Repair................................................................... 871 Remove and Disassemble...................................................... 871 Clean....................................................................... 871 Inspect..................................................................... 871 Assemble and Install........................................................ 871 Spindles, Bearings, and Tie Rods Repair......................................... 873 Remove and Disassemble...................................................... 873 Assemble and Install........................................................ 874 Steering Cylinder Repair........................................................ 875 Remove and Disassemble...................................................... 875 Clean and Inspect........................................................... 875 Assemble and Install........................................................ 876 Torque Specifications........................................................... 876 Troubleshooting................................................................. 877 Steering Housing and Control Unit....................................................... 878 toc................................................................................. 878 Steering Housing and Control Unit............................................... 878 General......................................................................... 880 Description..................................................................... 880 Operation....................................................................... 881 Steering Wheel and Column Assembly Repair....................................... 883 Assembly Components, Remove................................................. 883 Steering Control Unit, Disassemble.......................................... 886 Steering Control Unit, Clean................................................ 888 Steering Control Unit, Assemble............................................. 888 Assembly Components, Install................................................ 890 System Air Removal.............................................................. 891 Troubleshooting................................................................. 892 Steering System for AC Electric Lift Trucks............................................. 895 toc................................................................................. 895 Steering System for AC Electric Lift Trucks..................................... 895 General......................................................................... 897 Description..................................................................... 898 Steering Wheel and Column Assembly Repair....................................... 899 General..................................................................... 899 Assembly Components, Remove................................................. 901 Assembly Components, Install................................................ 902 Power Steering Motor and Pump................................................... 903 Description................................................................. 903 Remove...................................................................... 903 Disassemble................................................................. 906 Install..................................................................... 906 Power Steering Pump, Repair................................................. 906 Seal, Replace........................................................... 907 Steering System Air Removal..................................................... 908 Steering Pressure Check......................................................... 908 Steering Motor Circuits Check................................................... 909 Troubleshooting................................................................. 910 Tilt Cylinders.......................................................................... 914 toc................................................................................. 914 Tilt Cylinders.................................................................. 914 General......................................................................... 916 Description..................................................................... 916 Tilt Cylinder Repair............................................................ 916 Remove...................................................................... 916 Disassemble................................................................. 916 Clean....................................................................... 916 Assemble.................................................................... 916 Tilt Cylinders With O-Ring or Single-Lip Seals.......................... 916 Tilt Cylinders for XM and XMS Models.................................... 918 Tilt Cylinders for XL, XLS, and XL 3 Models............................. 919 Tilt Cylinders for H700-800A and Early Model H700-920B.................. 921 Install..................................................................... 922 Tilt Cylinders Using Chevron Packing.................................... 922 Install............................................................. 923 Tilt Cylinder Leak Check........................................................ 925 Tilt Cylinder Stroke and Mast Tilt Angle Adjustment............................. 927 Torque Specifications........................................................... 927 Piston Rod Nut.............................................................. 927 Retainer.................................................................... 928 Troubleshooting................................................................. 930 tables.............................................................................. 914 Table 1. Movement Rates (Maximum) for Tilt Cylinders............................ 926 Troubleshooting and Adjustments Using the AC Controls Program (ETACC)................... 933 toc................................................................................. 933 Troubleshooting and Adjustments Using the AC Controls Program (E................ 933 General......................................................................... 936 Computer Requirements....................................................... 936 Software, Install........................................................... 936 Language Selection.......................................................... 936 Demo Mode................................................................... 937 Connect PC to Lift Truck.................................................... 941 Starting AC Controls Program................................................ 943 Lift Truck Control Setup........................................................ 947 Change Lift Truck Serial Number or Hourmeter................................ 947 Setting Factory Default Values or Changing Lift Truck Parameters............ 949 Create New Custom Lift Truck Configuration.................................. 955 Lift Truck Configuration Properties......................................... 958 Import New Lift Truck Configuration From Disk............................... 961 Delete Custom Lift Truck Configuration or Password File..................... 963 Dash Display.................................................................... 966 Custom Display Languages.................................................... 966 Download Display Language................................................... 968 Clear Operator Log.......................................................... 968 Password Functions.............................................................. 971 Enable/Disable Password and Lift Truck Inspection Functions................. 971 Truck Inspection Checklist.............................................. 971 Password................................................................ 971 Password Properties......................................................... 971 Create New Password File.................................................... 976 Download Passwords.......................................................... 978 Upload Passwords............................................................ 978 Reports Menu.................................................................... 982 Devices Report.............................................................. 982 Custom Report............................................................... 982 Password Report............................................................. 982 Operator Report............................................................. 989 Current Settings Report..................................................... 992 Status Code Report.......................................................... 995 Status Codes Log............................................................ 998 Troubleshooting.................................................................1000 Diagnostics.................................................................1000 Help Menu.......................................................................1003 General.....................................................................1003 Contents....................................................................1003 Technical Support...........................................................1003 About Electric Truck AC Controls Program....................................1003
HYSTER E210 (V30ZMD E2.00-3.20XM E45-65Z) SERVICE MANUAL – PDF DOWNLOAD:
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