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

1,160 pages · Publication B219

$119.93
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Models
B219 (E30-35-40HSD2) Stand-Up
Manual type
Service Manual
Pages
1,160
Publication
B219
Condition
Brand new
Hyster B219 (E30-35-40HSD2) Stand-Up Forklift Service Manual, publication B219

What's inside

From the manual's own table of contents: 74 sections, 297 entries. See sample pages (PDF, 264 KB)

DC Motor Maintenance
Safety Precautions Maintenance and Repair
General
Brush and Commutator Inspection4 topics
  • Hydraulic Pump Motor and Traction Motor
  • Steering Pump Motor
  • Normal Commutator Surface
  • Commutator Problems
Brush Replacement
Stoning the Commutator
Motors Repair6 topics
  • Disassemble
    • Traction Motor and Hydraulic Pump Motor
    • Steering Pump Motor
  • Assemble
    • Traction Motor and Hydraulic Pump Motor
    • Steering Pump Motor
Brush Alignment, Traction and Hydraulic Motors
Tests for Damaged Field and Armature7 topics
  • Test for an Open Circuit in One Armature Winding
  • Test for Short Circuit in One Armature Winding
  • Test for Short Circuit to Armature Shaft
  • Test for Open Circuit in Field Coil
  • Test for Short Circuit in Field Coil
  • Test for Short Circuit Between Field and Motor Case
  • Brush Holder Test
Troubleshooting
Table 1. Normal Commutator Surfaces
Table 2. Commutator Problems
Table 3. Brush Wear Replacement Guide
Steering System
Description and Features
On-Demand Steering Circuit8 topics
  • Description
  • Steering Control Handle
    • Remove
    • Install
  • Steering Sensor
    • Test
    • Remove
    • Install
Steering Control Unit (SCU)4 topics
  • Inspect
  • Remove
  • Repair
  • Replace
Steering Pump and Motor Assembly3 topics
  • Disassemble
    • Assemble
  • Install
Power Steering Pump2 topics
  • Disassemble
    • Assemble
Steer Unit Actuator-Kordel™15 topics
  • Steering Actuator
    • Remove
    • Disassemble
    • Clean
    • Inspect
    • Assemble
    • Install
  • Steer Tire and Wheel
    • Remove
    • Install
  • Wheel Hub
    • Remove
    • Clean
    • Inspect
    • Install
Checks and Adjustments3 topics
  • Air in System
  • Operation Check
  • Steering Pressure
AC Motor Repair2 topics
  • Discharging the Capacitors for Lift Truck Models E30-40HSD 2 (B2
  • Discharging the Capacitors (All Other Models)
Traction Motor Repair30 topics
  • Remove
    • Disassemble
    • Electrical Connector Repair or Replacement
    • Clean
    • Inspect
    • Assemble
    • Install
    • Remove
    • Disassemble
    • Electrical Connector Repair or Replacement
    • Clean
    • Inspect
    • Assemble
    • Install
    • Remove
    • Disassemble
    • Clean
    • Inspect
    • Assemble
    • Install
    • Remove
    • Disassemble
    • Electrical Connector Repair or Replacement
    • Clean
    • Inspect
    • Assemble
    • Install
    • Remove
    • Clean
    • Install
Hydraulic Motor Repair28 topics
  • Remove
    • Disassemble
    • Electrical Connector Repair or Replacement
    • Clean
    • Inspect
    • Assemble
    • Install
    • Remove
    • Disassemble
    • Electrical Connector Repair or Replacement
    • Clean
    • Inspect
    • Assemble
    • Install
    • Remove
    • Disassemble
    • Electrical Connector Repair or Replacement
    • Clean
    • Inspect
    • Assemble
    • Install
    • Remove
    • Disassemble
    • Electrical Connector Repair or Replacement
    • Clean
    • Inspect
    • Assemble
    • Install
Show all 74 sections
Torque Specifications8 topics
  • Traction Motor for Lift Trucks J1.5-2.0XNT (J30-40XNT) (K160) an
  • Traction Motor for Lift Truck E30-40HSD 2 (B219)
  • Hydraulic Motor for Lift Trucks J1.5-2.0XNT (J30-40XNT) (K160) a
  • Hydraulic Motor for Lift Truck E2.2-3.5XN (E45-70XN) (A268)
  • Hydraulic Motor for Lift Truck J2.2-3.5XN (J45-70XN) (A276)
  • Hydraulic Motor for Lift Truck E1.6-2.0XN (E30-40XN) (A269)
  • Hydraulic Motor for Lift Truck E30-40HSD 2 (B219)
  • Hydraulic Motor for Lift Truck J4.0-5.0XN (J80-100XN) (A970) and
Table 1. Speed Sensor Connector
Table 2. Thermal Sensor Connector
Frame
Introduction2 topics
  • General
  • Discharging the Capacitors
Covers and Pads6 topics
  • Covers
    • Remove
    • Install
  • Pads
    • Remove
    • Install
Overhead Guard
Painting Instructions
Labels and Decals1 topic
  • Safety Labels
Battery6 topics
  • Battery Sizes
  • Battery Gate Interlock (Option)
    • Description
    • Removal
    • Installation
    • Adjustment
Table 1. Wheelbase
Brake System
Parking Brake
Hydraulic System2 topics
  • Hoses
  • Fittings
Multifunction Control Handle2 topics
  • Standard (Right/Left) Configuration
    • Optional (Push/Pull) Configuration
Manual Lowering1 topic
  • How to Lower Mast Manually
Main Hydraulic Control Valve9 topics
  • Check and Adjust
    • Check Manifold Pressures
    • Check Counterbalance Valve
  • Remove (Control Valve)
  • Repair (Control Valve)
    • Disassemble
    • Clean
    • Assemble
  • Install (Control Valve)
Lift Pump and Motor
Lift Pump
Hydraulic Tank3 topics
  • Clean
    • Steam Method
    • Trisodium Phosphate Method
Table 1. Pressure Settings
Table 2. Main Hydraulic Control Valve Cartridges
Table 3. Main Hydraulic Control Valve Cartridges
Electrical System
Major Electrical System Features18 topics
  • Integrated System
  • CANbus Advantages
  • CANbus Communications
    • Steering
    • Traction
    • Master Control Unit
  • Multifunction Control Handle
    • Standard (Right/Left) Configuration
    • Optional (Push/Pull) Configuration
    • Remove
    • Disassemble
    • Assemble
    • Install
  • Multifunction Displays
  • Speed
  • Steer Angle
  • Truck Hours
  • Operational Mode
Setup7 topics
  • Setup Instructions
    • ZAPI ACE0 Traction Control Unit
  • Normal Operation
    • Display
  • Diagnostics
    • Power-On Self-Test
    • Setup Menu Diagnostics
Checking Transistor Controller1 topic
  • Component Repair and Testing
AC Traction Motor Controller2 topics
  • Controller Removal
  • Low-Voltage Protection Function
Contactor and Electrical Panel Checks6 topics
  • Fuses
  • Contactor
    • General
    • Test
    • Contactor Tips
    • Disassemble and Assemble
Steer Position Sensor9 topics
  • Checking the Steer Position Sensor
  • Installing the Potentiometer
  • Position Steer Tire for Straight Travel
  • Potentiometer Position Adjustment
    • Dash Display Method
    • Voltmeter Method
    • Ohmmeter Method
  • Steer Calibration
  • Test
Steer Motor
Traction and Lift Pump Motors1 topic
  • Periodic Maintenance Checks
DC to DC Converter
Table 1. Potentiometer Specifications
User Interface4 topics
  • Button Keypad
    • LED Indicator Lights
    • LCD Screen
  • Dash Display Menu Access
Menu Navigation
Service-Level Menu23 topics
  • View Hour Meters
    • Truck Hours
    • Pump Hours
    • Tract Hours
  • Software Version
    • Master
    • Slave
    • Display
    • Pump
  • Password
    • Add Password
    • Delete Password
    • Edit Password
    • Operator Passw
    • Clear Oper Log
  • Diagnostic
    • Error Log
    • Run Diagnostics
    • No Run Diagnostics
  • Setup
    • Traction Settings
    • Hydraulic Settings
    • Truck Settings
Table 1. Service-Level Menu
Table 2. View Hour Meters Menu
Table 3. Software Version Menu
Table 4. Password Menu
Table 5. Diagnostic Menu
Table 6. Run Diagnostics Menu
Table 7. No Run Diagnostics Menu
Table 8. Setup Menu
Table 9. Traction Settings Menu
Table 10. Hydraulic Settings Menu (Display Software v3.0)
Table 11. Hydraulic Settings Menu (Display Software v3.02)
Table 12. Truck Settings Menu (Display Software v3.0)
Table 13. Truck Settings Menu (Display Software v3.02)

Inside this manual

Real pages from this service manual (1,160 pages). Open the sample pages (PDF, 263 KB)

Sample pages from the Hyster B219 (E30-35-40HSD2) Stand-Up Forklift Service Manual: Specifications, Diagram, Troubleshooting, Color page
  • Specifications, page 559: ASSEMBLE
  • Diagram, page 610: Figure 2. Schematic / Wiring Diagram (S/N B219N01920K ⇒) (Sheet 3 of 9)
  • Troubleshooting, page 1,120: DC Bus Voltage (Cont)
  • Color page, page 1,096: Brake Coil

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, 1,160 pages

Quantity one is the manual described above.

Fast free USA shipping

Ships in 1 business day.

60-day returns

Free if the mistake is ours. A manual ordered in error must come back unopened in its shrink-wrap; you pay return shipping and a 20% restocking fee applies. Return policy

Binder not included

Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.

Other editions and similar models

Hyster B219 (E30-35-40HSD2)Service Manual · 599886 · $79.87Hyster B219 (E30-35-40HSD2) Electric 3 Wheel Stand-UpService Manual · 599051 · $69.77

Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).