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Hyster B219 (E30-35-40HSD2) Forklift Service Manual

758 pages · Publication 599886

$79.87
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Models
B219 (E30-35-40HSD2)
Manual type
Service Manual
Pages
758
Publication
599886
Condition
Brand new
Hyster B219 (E30-35-40HSD2) Forklift Service Manual, publication 599886

What's inside

From the manual's own table of contents: 162 sections, 581 entries. See sample pages (PDF, 179 KB)

INTRODUCTION2 topics
  • GENERAL
  • DESCRIPTION
DISASSEMBLY AND ASSEMBLY11 topics
  • COUNTERWEIGHT
    • Removal
    • Installation
  • OVERHEAD GUARD
    • Removal
    • Installation
  • HOOD AND SEAT REMOVAL
  • ENGINE
    • Removal
    • INSTALLATION
  • FUEL TANK
REPAIRS3 topics
  • FUEL AND HYDRAULIC TANKS
    • Small Leaks
    • Large Leaks
OTHER REPAIRS13 topics
  • TILT CYLINDER MOUNTS
  • STEERING AXLE MOUNT
  • LABEL REPLACEMENT
  • FAN ASSEMBLY
    • Disassembly (S30–120E)
    • Disassembly (H60–110E)
    • Assembly (Both Series)
    • Fan Belt Adjustment
    • Installation
  • RADIATOR
    • Removal
    • Installation
    • Cleaning and Inspection
TROUBLESHOOTING14 topics
  • OPERATION
    • The Float System
    • The Idle System
    • The Main Metering System (GM 6-250)
    • The Power System (GM 6-250)
    • The Accelerator Pump System
    • Choke System
  • REMOVAL
  • DISASSEMBLY
  • Cleaning
  • ASSEMBLY
  • INSTALLATION
  • GOVERNOR (ELECTONIC) (IMPCO Type) (Later Units)
  • GOVERNOR (PNEUMATIC) (Early Units)
CHECKS AND ADJUSTMENTS13 topics
  • ADJUST THE CHOKE CONTROL
  • ADJUST THE IDLE SPEED
  • ADJSUT THE IDLE MIXTURE
  • ADJUST THE FAST IDLE
  • ADJUST THE THROTTLE LINKAGE,(Later Models)
  • ADJUST THE THROTTLE LINKAGE,(Early Models)
  • GOVERNOR (IMPCO Type) (Later GM 4-153 and 4-181 Engines Only)
    • Check the Governor
  • GOVERNOR (AISAN Type) (Early GM Engines Only)
    • Checks
    • Adjustments
  • GOVERNOR (HOOF Type) (Early GM Engines Only)
    • Adjust the Governor
THE LPG FUEL SYSTEM (IMPCO CA 50, CA 100)51 topics
  • Fuel Tank
    • Fuel Filter And Fuel Valve Unit
    • Vaporizer
    • The IMPCO CA 100 Carbureto
    • IMPCO CA 50 Carburetor
    • The Governor (GM Engines Only)
    • Governor With Electronic Controller
  • LPG TANK
    • Removal
    • Installation
  • REPLACE THE HOSES
  • HYDROSTATIC RELIEF VALVE
    • Removal and Installation
  • FILTER UNIT
    • Replacement Of the Fuel Filter Element
    • Replacement of the Diaphragm and Fuel Valve
  • VAPORIZER
    • Removal
    • Disassembly
    • Cleaning
    • Inspection
    • Assembly
    • Installation
  • CARBURETOR (IMPCO CA 100)
    • Removal
    • Disassembly
    • Cleaning
    • Assembly
    • Installation
  • CARBURETER (IMPCO CA 50)
    • Removal
    • Disassembly
    • Cleaning
    • Inspection
    • Assembly (See FIGURE 26.)
    • Installation
  • CHECK THE FILTER UNIT
  • CHECK THE VAPORIZER
    • Pressure Reducer Valve
    • Vapor Valve
  • ADJUST THE CARBURETOR
    • Idle Mixture
    • Idle Speed
    • Power Mixture
  • ADJUST THE GOVERNOR (GM Engines Only)
    • Checks
    • Main Adjusting Screw
    • Secondary Adjusting Screw
    • AISAN Governor
    • Adjustment, AISAN Governor
  • INSPECTION
CHECKS AND ADJUSTMENT19 topics
  • ADJUSTING THE CLUTCH PEDAL HEIGHT
  • ADJUSTING THE CLEARANCE OF THE RELEASE MECHANISM
  • ADJUSTING THE BY-PASS VALVE FOR COLD AIR
    • The Pinion Assembly
    • The Differential
    • Removing the Transmission (Both Methods)
    • Removing The Transmission Without Removing The Drive Axle
    • Removing The Transmission With The Drive Axle
    • Removing the Selector Rails and Forks
    • Removing the Hypoid Ring Gear and Differential
    • Removing the Gear Assemblies
    • Assembling The Hypoid Pinion and Ring Gear and Differential
    • Assembling the Range Countershaft
    • Assembling The Forward Countershaft
    • Assembling The Forward and Reverse Main Shaft
    • Assembling The Input Gear and Range Main Shaft
    • Installing the Differential Assembly
    • Installing the Selector Rails and Forks
  • LINKAGE ADJUSTMENTS
TROUBLESHOOTING - DIFFERENTIAL
TROUBLESHOOTING - TRANSMISSION
SPECIFICATIONS15 topics
  • REPAIRING THE CONTROL VALVE
    • Removal and Disassembly
  • MONOTROL PEDAL
    • Assembly and Installation
  • CHECKING THE MONOTROL PEDAL FOR LEAKAGE
  • STALL TEST
  • MONOTROL LINKAGE
  • CHECKING THE OIL PRESSURES
    • Clutch Pressure (Check Port "2")
    • Inching Pressure (Check Port "2")
    • Torque Converter Pressure (Check Port "3")
    • Modulator Spool/Clutch Engage Pressure (Check Port "4")
    • Bypass Valve for Cold Oil
  • CHECKING THE POWERSHIFT ELECTRICAL CIRCUIT
  • CHECKING THE CIRCUIT FOR THE DIRECTION CONTROL LEVER
PRESSURE TESTS29 topics
  • STEERING AXLES WITH STUB SHAFT MOUNTS
    • Removal
    • Installation
  • ELECTRIC LIFT TRUCK WITH RUBBER MOUNTS
    • Removal
    • Installation
  • ELECTRIC LIFT TRUCK WITH RUBBER MOUNTS (E30-50B, E60BS AFTER AUGUST 1981)
    • Removal
    • Installation
  • WHEELS AND HUBS
    • Removal and Disassembly
    • Cleaning
    • Assembly And Installation
  • SPINDLES, BEARING AND TIE RODS
    • Removal And Disassembly
    • Cleaning
    • Assembly And Installation
  • STEERING CYLINDER
    • Removal And Disassembly
    • Cleaning
    • Assembly And Installation
  • CENTER PIVOT OR RUBBER MOUNTS
  • SPINDLE AND HUB
  • DESCRIPTION AND OPERATION
  • REMOVAL AND DISASSEMBLY
  • ASSEMBLY AND INSTALLATION
  • ADJUSTING THE RELIEF VALVE
    • Steering System
    • Lift System
REPAIR10 topics
  • HYDRAULIC TANK
  • MAIN HYDRAULIC PUMP
  • FLOW REGULATOR VALVE
  • STEERING CONTROL UNIT
  • CONTROL VALVES
  • LIFT AND TILT CYLINDERS
  • ADJUSTING THE STEERING RELIEF VALVE PRESSURE
  • ADJUSTING THE LIFT AND TILT RELIEF VALVE PRESSURE
  • ADJUSTING THE TWO-STAGE RELIEF VALVE
  • ADJUSTING THE AUXILIARY RELIEF VALVE
ELECTRICAL SYSTEM COMPLETELY DEAD
STARTER DOES NOT CRANK AND SOLENOID DOES NOT PULL IN
STARTER DOES NOT CRANK; SOLENOID PULLS IN, DOES NOT CHATTER
STARTER SOLENOID CLICKS IN AND OUT WHILE ATTEMPTING TO CRANK
STARTER CRANKS SLOWLY
STARTER CRANKS AT NORMAL SPEED, BUT ENGINE DOES NOT START
BATTERY GOES DEAD OVERNIGHT OR OVER WEEKEND
CHARGING SYSTEM DOES NOT FUNCTION
ALTERNATOR CHARGES AT A RATE ALTHOUGH BATTERY IS LOW
BATTERY IS BEING OVERCHARGED
ONE OR MORE DASH GAUGES DO NOT WORK
Show all 162 sections
HORN DOES NOT BLOW
POWERSHIFT TRANSMISSION WILL NOT ENGAGE
ELECTRICAL SCHEMATIC S20-30A, H20-30E
ELECTRICAL S30-50C
ELECTRICAL SCHEMATIC H30-60H GASOLINE & LPG
ELECTRICAL SCHEMATIC H30-60H DIESEL
ELECTRICAL SCHEMATIC H60-90C GASOLINE & LPG
ELECTRICAL SCHEMATIC H60-90C DIESEL
ELECTRICAL SCHEMATIC S30-60ES
ELECTRICAL SCHEMATIC S60-120E
ELECTRICAL SCHEMATIC S125-150A GASOLINE & LPG
ELECTRICAL SCHEMATIC S125-150A DIESEL
ELECTRICAL SCHEMATIC H110-150F GASOLINE & LPG
ELECTRICAL SCHEMATIC H110-150F DIESEL
ELECTRICAL SCHEMATIC H150-275H, P150200B GASOLINE & LPG
ELECTRICAL SCHEMATIC H150-275H, P150-200B DIESEL
ELECTRICAL SCHEMATIC H300A
ELECTRICAL SCHEMATIC H300-350B
ELECTRICAL SCHEMATIC H360-620B PERKINS DIESEL
ELECTRICAL SCHEMATIC H360-620B DETROIT DIESEL
ELECTRICAL SCHEMATIC H700-800A
ELECTRICAL SCHEMATIC P40-50A GASOLINE
ELECTRICAL SCHEMATIC P40-50A DIESEL
ELECTRICAL SCHEMATIC P60-80A GASOLINE
ELECTRICAL SCHEMATIC P60-80A DIESEL
ELECTRICAL SCHEMATIC KE GAS GASOLINE
ELECTRICAL SCHEMATIC KE DIESEL
ELECTRICAL SCHEMATIC M200-400H GASOLINE
ELECTRICAL SCHEMATIC M200-400H DIESEL
ELECTRICAL SCHEMATIC M600A21 topics
  • FORKS
  • CARRIAGE
    • Removal
  • SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
    • Installation
  • MASTS
    • Removal
    • Disassembly
    • Cleaning and Inspection
    • Assembly
  • CHECKING FOR LEAKS IN THE LIFT SYSTEM
  • ADJUSTING THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE
  • LIFT CHAIN ADJUSTMENTS
  • MAST ADJUSTMENTS
    • Guide Shoe Adjustment
  • CARRIAGE ADJUSTMENT
  • STANDARD MASTS (Mast Assemblies Having Less Than Full Free-Lift.)
  • FULL FREE-LIFT MASTS
  • THREE-STAGE MASTS
  • FOUR-STAGE MASTS
  • SEQUENCE VALVE
VISTA TWO-STAGE MASTS
VISTA THREE-STAGE MASTS1 topic
  • MAINTENANCE SCHEDULE
MAINTENANCE PROCEDURES EVERY 8 HOURS OR DAILY16 topics
  • CHECK WITH THE ENGINE STOPPED
    • Hydraulic Tank
    • Air Cleaner
    • Engine Oil
    • Fuel Filter (Diesel)
    • Battery
    • Cooling System
    • Drive Belts
    • Tires And Wheels
    • Forks
    • Lift Chains
  • CHECKS WITH THE ENGINE RUNNING
    • Start the engine
    • Transmission
    • Mast Operation
    • Brakes
EVERY 350 HOURS OR TWO MONTHS9 topics
  • ENGINE OIL AND FILTER (PERKINS ENGINE)
  • ENGINE OIL AND FILTER (GASOLINE ENGINE)
  • PRIMARY FUEL FILTER (PERKINS ENGINE)
  • BRAKE FLUID
  • HYDRAULIC TANK BREATHER
  • COOLING FAN
  • STEERING AXLE
  • UNIVERSAL JOINT
  • OTHER LUBRICATION POINTS
EVERY 1000 HOURS OR SIX MONTHS7 topics
  • FINAL FUEL FILTER (DIESEL)
  • REMOVING AIR FROM THE DIESEL FUEL SYSTEM
  • IGNITION SYSTEM (GAS ENGINE)
  • PCV VALVE (GAS ENGINE)
  • CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM
    • Check The Lift Cylinders For Leaks
    • Check The Tilt Cylinder For Leaks
EVERY 2000 HOURS OR YEARLY9 topics
  • PCV VALVE (DIESEL ENGINE)
  • DIFFERENTIAL
  • ADJUSTING THE OIL CLUTCH PEDAL
  • OIL FILTER FOR THE POWERSHIFT TRANSMISSION OR THE OIL CLUTCH
  • HYDRAULIC SYSTEM
    • Changing The Hydraulic Oil Filter
    • Changing The Hydraulic Oil
  • CHANGE THE GASOLINE FUEL FILTER
  • CHANGE THE FUEL FILTER FOR LPG
WHEELS AND TIRES4 topics
  • DRIVE TIRES
  • STEERING TIRES
    • Disassembly
    • Assembly
GENERAL
TRAVEL SPEEDS
HYDRAULIC SYSTEM
TIRE PRESSURE
CAPACITIES
ELECTRICAL
LIFT SPEEDS
LOWERING SPEEDS
ENGINE, GENERAL INFORMATION
ENGINE, SERVICE, PERKINS 2.482
ENGINE, SERVICE, GM 6-250
ELECTRICAL WIRING DIAGRAM (GAS AND LPG)
ELECTRICAL WIRING DIAGRAM (DIESEL)
HYDRAULIC SCHEMATIC-EARLY UNITS
HYDRAULIC SCHEMATIC-LATER UNITS
Cooling System
Safety Precautions Maintenance and Repair
Description4 topics
  • Radiator Cap
  • Thermostat
  • Water Pump
  • Fan and Fan Shroud
Cooling System Checks1 topic
  • Exhaust Leaks
Radiator Cleaning3 topics
  • Drain
  • Clean
  • Fill
GM Engines
Engine Removal and Installation
Cylinder Head and Valve Mechanism Repair11 topics
  • Cylinder Head, Remove
  • Cylinder Head, Disassemble
  • Clean and Inspect
  • Valves and Valve Seats
  • Studs for Rocker Arms
  • Hydraulic Valve Lifters, Replace
  • Hydraulic Valve Lifters, Clean and Inspect
  • Cylinder Head, Assemble
  • Cylinder Head, Install
  • Valve Clearance, Adjust
  • Rocker Arm Cover, Install
Timing Gear Cover Repair2 topics
  • Remove
  • Install
Camshaft Repair4 topics
  • Inspect
  • Camshaft Bearing
    • Remove
    • Install
Distributor Repair
Lubrication System Repair8 topics
  • Oil Sump
    • Remove
    • Install
  • Oil Pump
    • Remove
    • Disassemble and Repair
    • Assemble
    • Install
Piston and Connecting Rod Assemblies Repair8 topics
  • Connecting Rod Bearings, Replace
  • Piston and Connecting Rod Assemblies, Remove
  • Piston and Connecting Rod Assemblies, Disassemble
  • Piston, Clean and Inspect
  • Cylinder Bores, Inspect and Repair
  • Piston Rings, Inspect
  • Piston and Connecting Rod Assemblies, Assemble
  • Piston and Connecting Rod Assemblies, Install
Crankshaft Repair5 topics
  • Main Bearings, Replace
  • Oil Seal for Rear Main Bearing, Replace (GM 4-181 and 3.0L Only)
  • Oil Seal for Rear Main Bearing, Replace (Engines That Have Two-P
  • Inspect and Repair
  • Main Bearing and Journal Clearance, Check
Flywheel and Flywheel Housing Repair1 topic
  • Ring Gear, Replace
Cooling System Repair3 topics
  • Coolant Pump
  • Fan Drive
  • Viscous Fan Drive
Engine Specifications10 topics
  • Engine Data
  • Cylinder Head
  • Hydraulic Valve Lifter
  • Camshaft
  • Pistons
  • Cylinder Bore
  • Crankshaft
  • Connecting Rods
  • Cooling System
  • Lubrication System
Torque Specifications
Main Control Valve
Operation6 topics
  • Lift Spool
  • Tilt Spool
    • Tilt Backward
    • Tilt Forward
  • Single-Stage Relief Valve
  • Two-Stage Relief Valve
Main Control Valve Repair2 topics
  • Remove and Disassemble
  • Assemble
Single-Stage Relief Valve Adjustment
Two-Stage Relief Valve
Auxiliary Control Valve Relief Valve Adjustment (H60-110E Only)
Table 1. Relief Pressures (Oil temperature at 55 to 66 C ( 131 t
Alternator with Regulator
Alternator Repair10 topics
  • Alternator Type A
    • Remove and Disassemble
    • Clean
    • Assemble
    • Install
  • Alternator Type B
    • Remove and Disassemble
    • Clean
    • Assemble
    • Install
General Check and Adjustment
Low Output Check (Type A or Type B)
High Output Check (Type A or Type B)
Brushes Circuit Check2 topics
  • Delco Alternators
  • Motorola Alternators
Diodes Check
Diode Bridge Check1 topic
  • Delco and Leece-Neville Alternators
Rotor Field Winding Check
Stator Windings Check
Voltage Regulator Check
High Energy Ignition (HEI) System3 topics
  • Disassemble
  • Install, If Crankshaft WAS NOT Rotated when Distributor was Remo
  • Install, If Crankshaft WAS Rotated when Distributor was Removed
Ignition Coil Replacement6 topics
  • Some Four- and Six-Cylinder Models
    • Remove
    • Install
  • V8, Some Four- and Six-Cylinder Models
    • Remove
    • Install
Electronic Module Replacement
Sensing Coil Replacement
Spark Plugs Replacement
Visual Check
High Voltage Wires Check
Ignition Coil Check3 topics
  • Coil in Distributor Cap Design
  • Separate Coil Design
  • Sensing Coil, Check
Electronic Module Check
Ignition Timing Adjustment
GM V8-366 (6-liter) Ignition System Check
GM V6-LPG (4.3 liter) GM V6-LPG (4.3 liter) Ignition Timing and
Drive Axle
Drive Axle Repair2 topics
  • Disassemble (Type 1 Shown)
  • Assemble (Type 1 Shown)
Steering Control Unit
Steering Wheel and Column Assembly Repair
Steering Column Assembly Repair7 topics
  • Type A Steering Column Assembly
    • Remove and Disassemble
    • Assemble and Install
  • Type B Steering Column Assembly
    • Remove and Disassemble
    • Assemble and Install
    • Steering Control Unit
System Air Removal
Hydraulic Gear Pumps2 topics
  • Flow Control Valve
  • Relief Valve
Hydraulic Gear Pump Repair
Pump Output Check2 topics
  • Method No. 1
  • Method No. 2
Hydraulic System Air Check
Tilt Cylinders
Tilt Cylinder Repair5 topics
  • Tilt Cylinders With O-Ring or Single-Lip Seals
    • Tilt Cylinders for XM and XMS Models
    • Tilt Cylinders for XL, XLS, and XL 3 Models
    • Tilt Cylinders for H700-800A and Early Model H700-920B
    • Tilt Cylinders Using Chevron Packing
Tilt Cylinder Leak Check
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment2 topics
  • Piston Rod Nut
  • Retainer
Table 1. Movement Rates (Maximum) for Tilt Cylinders
Starter
Description and Operation
Starter Repair
General Checks and Adjustments
Instrument Panel Indicators and Senders14 topics
  • Steering Column Gauges, Meters, and Indicators
  • LED Display Panel
    • Battery Discharge Indicators
    • Brush Wear Indicators
    • Motor Temperature Indicators
  • LX Series Display Panel
    • Hourmeter Functions
    • Battery Indicator Function
    • Status Code Function
  • ZX Series Display Panels
    • Display Panel
    • Basic Display Panels
    • Performance Display
    • Brush Wear Indicators
Adjustments - General
Replacement - General Information
Meter Replacement
Sender Replacement8 topics
  • Fuel Level Sender
  • Pressure and Temperature Sender
  • Seat Sensor, Operator Presence System (OPS)
    • Remove
    • Install
  • Operator Presence System Module Replacement
    • Remove
    • Install
ITW Display Panel Replacement
Column Mount Display Panel (EV-100/200ZX Motor Controllers) Repl7 topics
  • Display Panel Assembly, Replace
  • Indicator LEDs
  • Battery Indicators
  • Digital Display (Performance Display Panel Only)
  • Status Code or Performance Level Switches and Indicator LEDs (Pe
  • Basic Display Panel, Replace Parts
  • Performance Display Panel, Replace Parts
Dash Mount Display Panel (EV100/200ZX Motor Controllers) Replace4 topics
  • Remove and Replace
  • Meter Specifications
  • Sender Specifications
  • Meter
Troubleshooting for Operator Presence System
Table 1. Troubleshooting Procedure for Operator Presence Module
Electrical Warning Devices4 topics
  • Operator-Controlled Horns
  • System Warning Lights, Buzzers, and Bells
  • Reverse Warning Horns
  • Warning Lights
Replacement5 topics
  • Horns or Bells, Replace
  • Horn Relay or Buzzer, Replace
  • Warning Lights/Bulbs, Replace
  • Light Assemblies, Replace
  • Flashing Units, Replace
Lift Cylinders
Safety Procedures When Working Near Mast4 topics
  • Lowering Control Valve
  • Cylinders (General)
    • Retainer, Install
  • Cylinders (Two-Speed)
Lift Cylinder Repair10 topics
  • Lift Cylinder Removal Without Removing Mast
    • Standard Masts With Main Lift Cylinder Fastened to Crossmember o
    • Standard and Full Free-Lift Masts With Lift Cylinder Fastened to
    • Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift
  • Lift Cylinder Installation in Mast
    • Standard Masts With Main Lift Cylinder Fastened to Crossmember o
    • Standard and Full Free-Lift Masts With Lift Cylinder Fastened to
  • Chevron-Style Packing
    • Chevron-Style Packing Installation on Piston
    • Chevron-Style Packing Installation in Packing Gland
Lift Cylinders for VISTA® Masts3 topics
  • Lowering Control Valve
    • Main Lift Cylinders
    • Free-Lift Cylinder
Lift System Leak Check
Table 1. Lift Trucks With Two-Speed Lift Cylinders
Table 2. Cylinder Retainer Torque Specifications and Weight Guid

Inside this manual

Real pages from this service manual (758 pages). Open the sample pages (PDF, 179 KB)

Sample pages from the Hyster B219 (E30-35-40HSD2) Forklift Service Manual: Diagram, Troubleshooting, Specifications
  • Diagram, page 264: FIGURE 23. ELECTRICAL SCHEMATIC P60–80A DIESEL
  • Troubleshooting, page 451: Troubleshooting
  • Specifications, page 693: Troubleshooting

This is a service manual

Here's how it compares to the other manual types.

This manual

Service manual

Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.

Operator's manual

Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.

Parts manual

Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.

Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.

What it's used for

Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.

Service shops and owner/operators who repair their own equipment

Identifying correct parts and seeing how assemblies come apart and go back together

Keeping equipment running with less downtime

Factory manual, 758 pages

Quantity one is the manual described above.

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Ships in 1 business day.

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Other editions and similar models

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