Hyster E210 (V30ZMD) Forklift Service Manual
956 pages · Publication 1640596
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- Models
- E210 (V30ZMD)
- Manual type
- Service Manual
- Pages
- 956
- Publication
- 1640596
- Condition
- Brand new
What's inside
From the manual's own table of contents: 154 sections, 604 entries. See sample pages (PDF, 315 KB)
Drive Axle, Speed Reducer, and Differential
Safety Precautions Maintenance and Repair
General
Description
Drive Axle, Speed Reducer, and Differential Repair9 topics
- Drive Axle, Remove
- Drive Axle, Disassemble
- Speed Reducer and Differential, Disassemble
- Clean
- Inspect
- Assemble
- Speed Reducer and Differential, Assemble
- Drive Axle, Assemble
- Drive Axle Assembly, Install
Torque Specifications13 topics
- Wheel Nuts
- Axle Shaft Capscrews
- Axle Hangers to Frame
- Back Plate to Axle Mount Capscrews
- Wheel Cylinder Capscrews
- Ring Gear to Differential Case
- Differential Case Halves
- Bearing Cap Capscrews
- Retainer Capscrews
- Axle Housing to Differential Housing
- Pinion Nut
- Speed Reducer Housing to Differential Housing
- Traction Motor to Transmission
Troubleshooting
Table 1. Adjustment of Shims for Pinion Assembly
Table 2. Ring and Pinion Tooth Contact Adjustment
DC Motor Maintenance
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 Repair5 topics
- Disassemble
- Traction Motor and Hydraulic Pump Motor
- Steering Pump Motor
- 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
Table 1. Normal Commutator Surfaces
Table 2. Commutator Problems
Table 3. Brush Wear Replacement Guide
Mast
Mast Weldments
Carriages
Two-Stage Mast2 topics
- Description
- Operation
Three-Stage Mast
Show all 154 sections
Lift Cylinders1 topic
- Lowering Control Valve
Main Cylinder Repair
Free-Lift Cylinder Repair
Safety Procedures When Working Near Mast
Load Backrest Extension, Carriage, Load Rollers, Side Rollers, a6 topics
- Load Backrest Extension, Remove and Install
- Carriage Assembly, Remove and Install
- Carriage Load Rollers, Remove and Install
- Side Rollers, Disassemble and Assemble
- Fork, Replace
- Hook-Type Forks
Two-Stage Mast Assembly15 topics
- Remove
- Clean and Inspect
- Lift Cylinders, Remove and Install Dual-Lift Cylinders
- Lift Cylinder, Remove and Install Single Main-Lift Cylinders
- Remove
- Install
- Inner Mast Assembly, Remove and Install
- Hoses, Replace
- Hose and Cable Sheaves, Replace
- Two-Stage Lift Chains
- Remove and Install
- Clean and Inspect
- Two-Stage Chain Sheave, Remove and Install
- Load Rollers and Wear Plugs, Remove and Install
- Two-Stage Mast Assembly, Install
Three-Stage Mast Assembly14 topics
- Three-Stage Mast Assembly, Remove
- Free-Lift Cylinder, Remove and Install
- Main Cylinders (Standard), Remove and Install
- Inner and Intermediate Mast Assemblies, Remove and Install
- Free-Lift Hose Sheave
- Carriage Sheaves
- Three-Stage Lift Chains, Remove and Install
- General
- Free-Lift Chains
- Main-Lift Chains
- Three-Stage Chain Sheaves, Disassemble and Assemble
- Free-Lift Chain Sheaves
- Main-Lift Chain Sheaves
- Three-Stage Mast Assemble, Install
Mast Operation Check
Hydraulic System Leaks Check
Lift Chains Check2 topics
- General
- Lubrication
Mast Adjustments6 topics
- Adjust Wear Plugs - Mast
- Adjust Free-Lift Chain (Three-Stage Only)
- Adjust Main-Lift Chains
- Two-Stage
- Three-Stage
- Adjust Wear Strips
Carriage Adjustments3 topics
- Adjust Wear Plug - Carriage
- Adjust Side Rollers - Carriage
- Adjust Thrust Rollers - Carriage
Frame3 topics
- Main Frame
- Other Frame Weldments
- Overhead Guard
Overhead Guard Replacement1 topic
- Install
Battery and Operator Restraint System, Hood and Seat Brake, and7 topics
- Battery Restraint System
- Hood
- Hood With E-Hydraulics
- Seat Brake
- Operator Restraint System and Seat Assembly
- Automatic Locking Retractor (ALR)
- Emergency Locking Retractor (ELR)
Counterweight Replacement
Traction Motor Replacement
Hydraulic Tank Repair6 topics
- Steam Method
- Chemical Solution
- Additional Preparations for Repair
- Small Leaks, Repair
- Large Leaks, Repair
- Preparations for Usage After Repair
Painting Instructions
Safety Label Replacement
Battery Specifications
Table 1. Counterweights
Hydraulic System
Operation6 topics
- Hydraulic Gear Pump
- Rotator Actuator Valve
- Steering Pump
- Steam Method
- Chemical Solution Method
- Additional Methods for Tank Repair
Filter Replacement8 topics
- Remove
- Install
- Remove
- Install
- Remove
- Install
- Remove
- Install
Hydraulic Pump Repair2 topics
- Pump Seal Replace and Pump Assemble
- Assemble Pump on Motor
Main Control Valve Repair
Steering Pump Repair1 topic
- Pump, Assemble and Install
Rotary Actuator Valve Repair1 topic
- Disassemble, Clean, and Inspect
Steering Control Unit Replacement
Steering Cylinder Repair
Main Control Valve Check and Adjust
Steering Relief Valve Check and Adjust
Specifications6 topics
- Relief Valve Pressures*
- Hydraulic Tank Capacity (dipstick full mark)
- Hydraulic Pump Capacities - All Models Except E3.50-5.50XL, E4.5
- Hydraulic Pump Capacities - Models E3.50-5.50XL, E4.50XLS (E70-1
- Steering
- Steering Housing and Steering Control Unit
Brake System
Description and Operation3 topics
- Service Brakes
- Master Cylinder
- Parking Brake
Service Brakes Repair3 topics
- Remove and Disassemble
- Assemble and Install
- Adjust
Parking Brake Repair
Master Cylinder Repair
Seat Brake Assembly12 topics
- Seat Brake, Adjust - Lift Truck Models E2.00-3.20XM (E45-65XM, E
- Brake Switch, Adjust - Lift Truck Models E2.00-3.20XM (E45-65XM
- Electric Seat Brake, Adjust for Lift Truck Model E2.00-3.20XM (E
- Electric Seat Brake Adjustment With Handle For Lift truck Models
- Remove
- Clean
- Inspect
- Install
- Adjustments
- Solenoid Adjustment
- Traction cutoff Switch Adjustment
- Cable Adjustment
Service Brakes Adjustment
Brake Pedal Adjustment
Master Cylinder Adjustment
Brake System Air Removal
Parking Brake Not Applied Switch Test
Manual hydraulic Control Valve3 topics
- Lift Section
- Auxiliary Section
- Relief Valve
Control Lever Linkage Repair
Control Valve Linkage Repair
Pressure Relief Valve Check and Adjustment2 topics
- Primary Relief Valve
- Secondary Relief Valve
Steering Axle
Steering Axle Assembly Replacement
Wheels Repair
Spindles, Bearings, and Tie Rods Repair
Steering Housing and Control Unit
Steering Wheel and Column Assembly Repair5 topics
- Assembly Components, Remove
- Steering Control Unit, Disassemble
- Steering Control Unit, Clean
- Steering Control Unit, Assemble
- Assembly Components, Install
System Air Removal
Steering System for AC Electric Lift Trucks
Power Steering Motor and Pump2 topics
- Power Steering Pump, Repair
- Seal, Replace
Steering System Air Removal
Steering Pressure Check
Steering Motor Circuits Check
Electrical System (Trucks With AC Controllers)2 topics
- Features of the Display Panels
- Other Control Components
Display Panel and Key Switch Replacement2 topics
- Display Panel, Replace
- Key Switch, Replace
Controller Replacement2 topics
- Traction and Pump Motor Controller Replacement
- Master Controller, Replace
Control Components Replacement26 topics
- Start Switch, Replace
- Brake Light Switch, Replace
- Seat Switch, Replace
- Parking Brake Switch, Replace
- MONOTROL Pedal Direction Switches, Replace
- Steering Column Direction Control Switches, Replace
- Remove
- Install
- Brake Fluid Switch, Replace
- Brush Wear and Over Temperature Sensors (DC Pump Motor Only)
- Rocker Switches for Lights, Replace
- Accelerator Position Sensor, Replace
- On-Demand Steering Sensor, Replace
- Lights, Converter, Relay, and Reverse Alarm
- Brake, Tail, and Reverse Light Assembly, Replace
- Strobe Light Assembly, Replace
- Wire Harness Repair
- Front, Rear Driving Light or Spot Light Assemblies, Replace
- Converter, Replace
- Reverse Relay, Replace
- Backup Alarm, Replace
- Horn and Horn Button, Replace
- Horn Replacement for Lift Trucks E3.50-5.50XL, E4.50XLS (E70-120
- Horn Switch and Cover, Replace
- Hydraulic Pump Switches
- Fan Power Supply, Replace
Control and Power Fuse Check1 topic
- Fuse Locations
Brake Light Switch Adjustment
Seat Switch Check
Seat Brake Adjustment
Parking Brake Switch Adjustment
Direction Switches Check2 topics
- MONOTROL Pedal
- Steering Column
MONOTROL Pedal or Accelerator Pedal Adjustment
Accelerator Position Sensor Adjustment and Start Switch Adjustme2 topics
- Acceleration Position Sensor, Adjust
- Start Switch, Adjust
Table 1. Wire Splice Size
AC Motor Controllers/Display Panel5 topics
- AC Motors
- Motor Controllers
- Master Controller
- Dash Display
- Controller Area Network Bus (CANbus)
Master Controller Checks and Adjustments
Function Settings1 topic
- Function Numbers
Function Descriptions20 topics
- Function Number 1 BATTERY VOLTAGE
- Function Number 2 EXTENDED SHIFT
- Function Number 3 ACCELERATION 1
- Function Number 4 ACCELERATION 2
- Function Number 5 TOP SPEED LIMIT
- Function Number 6 REGEN BRAKING
- Function Number 7 AUTO DECELERATION
- Function Number 8 BDI ADJUSTMENT
- Function Number 9 LIFT INTERRUPT
- Function Number 10 POWER STEERING TIME DELAY
- Function Number 11 SERVICE REMINDER
- Function Number 12 CUSTOM
- Function Number 13 PUMP SPEED 1
- Function Number 14 PUMP SPEED 2
- Function Number 15 PUMP SPEED 3
- Function Number 16 PUMP ACCELERATION
- Controller Status Light Emitting Diodes (LEDs)
- Master Controller
- AC Motor Controllers
- Status Codes
AC Motor Controllers Status Code Charts6 topics
- Troubleshooting When Dash and/or Lift Truck is not Operational
- Typical Symptoms
- Truck Runs but Dash Display is not Operational, or Only Displays
- Truck Does Not Run and Dash is Not Operational or Only Displays
- Hydraulics Operate Normally, Traction Does Not Operate Correctly
- Traction Operates Normally, Hydraulics do Not Operate Correctly
AC Transistor Motor Controller Replacement8 topics
- General Maintenance Instructions
- Special Precautions
- Fuses
- Fan Test
- Contactors
- Repair
- Thermal Sensors
- Motor Controller, Replace
Display Panel2 topics
- Premium Display Panel
- Standard Display Panel
Display Functions and Features9 topics
- Key-On Initialization
- Standard Display
- Premium Display
- Lift Truck Inspection Function
- Access to Service Functions
- Service Functions
- Performance Modes
- Battery Discharge Indicator (BDI)
- Hourmeter
Dash Display Service Menu Navigation2 topics
- Moving Through Menu Selections
- Editing and Adding Information
Table 5. List of Status Codes
Table 6. 42-Pin Connections/Descriptions for Master Controller
Table 7. Pin Connections/Descriptions for 72/80 (Gen IV) Volt Mo
Table 8. Pin Connections/Descriptions for 36/48 and 72v/80v (Gen
Troubleshooting and Adjustments Using the AC Controls Program (E6 topics
- Computer Requirements
- Software, Install
- Language Selection
- Demo Mode
- Connect PC to Lift Truck
- Starting AC Controls Program
Lift Truck Control Setup6 topics
- Change Lift Truck Serial Number or Hourmeter
- Setting Factory Default Values or Changing Lift Truck Parameters
- Create New Custom Lift Truck Configuration
- Lift Truck Configuration Properties
- Import New Lift Truck Configuration From Disk
- Delete Custom Lift Truck Configuration or Password File
Dash Display3 topics
- Custom Display Languages
- Download Display Language
- Clear Operator Log
Password Functions7 topics
- Enable/Disable Password and Lift Truck Inspection Functions
- Truck Inspection Checklist
- Password
- Password Properties
- Create New Password File
- Download Passwords
- Upload Passwords
Reports Menu8 topics
- Devices Report
- Custom Report
- Password Report
- Operator Report
- Current Settings Report
- Status Code Report
- Status Codes Log
- Diagnostics
Help Menu2 topics
- Technical Support
- About Electric Truck AC Controls Program
Electrical Diagrams
Periodic Maintenance7 topics
- Serial Number Data
- How to Move Disabled Lift Truck
- How to Tow Lift Truck
- How to Put Lift Truck on Blocks
- How to Raise Drive Tires
- How to Raise Steering Tires
- How to Clean a Lift Truck
Maintenance Schedule
Maintenance Procedures Every 8 Hours or Daily20 topics
- How to Make Checks With Key OFF
- Tires and Wheels
- Forks
- Mast, Carriage, Lift Chains, Header Hoses, and Traverse Chains
- Safety Labels
- Steering Column Latch
- Operator Restraint System
- Battery Restraint System J2.00-3.20XM (J40-65Z) (A416) Lift Truc
- Battery
- Attachment
- Hydraulic System
- How to Make Checks With Key ON
- Horn, Lights, and Alarm
- Steering System
- Service Brakes
- Parking Brake
- Control Levers and Pedals
- Direction and Speed Control Pedals
- Lift System Operation
- Oil Leaks
First Service After First 100 Hours of Operation1 topic
- Change Filter for Hydraulic Oil
Maintenance Procedures Every 250 Hours or 6 Weeks8 topics
- Steering King Pins E1.50-2.00XM (E114/F114) Trucks Only
- Steering Tie Rods and Spindles
- Attachment Load Rollers, Lubricate
- Attachment Main Load Bearings and Roller Bearings
- Attachment Track Assembly
- Traverse Chain Adjustment
- Pivot Boom Chain Tension Check
- Attachment Hydraulic Hoses
Maintenance Procedures Every 500 Hours or 3 Months11 topics
- Differential and Speed Reducer V30ZMD (D210/E210); E2.00-3.20XM
- Wheel Nut Torques
- Header Hose Checks
- Mast Lubrication
- Forks
- Remove
- Inspect
- Install
- Adjust
- Parking Brake Adjustment
- Seat Brake Operations Check
Maintenance Procedures Every 1000 Hours or 6 Months16 topics
- Lift Chains
- Wear Check
- Lift Chain Lubrication
- Check Upper and Lower Bearings, Integral Sideshift Carriage
- Steering Axle Spindles
- Hydraulic Tank Breather
- Differential and Speed Reducer J2.00-3.20XM (J40-65Z) (A416)
- Attachment Main Load Bearings
- Traverse Chain
- Attachment Pivot Boom Chain
- Pivot Boom Shaft Fitting, Lubricate
- Attachment Moving Parts and Structural Assemblies
- Other Lubrication
- Electrical Inspection
- Contactors
- Motor Brushes (DC Pump)
Maintenance Procedures Every 2000 Hours or Yearly12 topics
- Change Filter for Hydraulic Oil
- Change Hydraulic Oil
- Differential and Speed Reducer
- Brake Fluid Replacement
- Steering Tie Rods and Spindle Lift Truck Models E25-35Z, E40ZS (
- Wheel Bearings
- Steer Wheels, Lubrication
- Drive Wheels, Lubrication
- Replace Upper and Lower Bearings, Integral Sideshift Carriage
- Limited Switch Roller Shafts, Traverse Attachment
- Attachment Roller Bearings
- Pivot Boom Assembly
Battery Maintenance2 topics
- How to Charge Battery
- General
Lift and Tilt System Leak Check3 topics
- Lift Cylinders Leak Check
- Tilt Cylinders Leak Check
- WHEN WORKING NEAR THE MAST ALWAYS
Lift Chain Adjustments
Welding Repairs
Overhead Guard Changes
Wheels and Tire Maintenance15 topics
- Remove Wheels From Lift Truck
- Remove and Install Tire on Wheel
- Remove Wheels From Lift Truck
- Remove Wheel From Pneumatic Tire
- Install Three- or Four-Piece Wheel in Pneumatic Tire
- Add Air to Tires
- Wheels, Install
- Solid Rubber Tires on Pneumatic Wheels
- Remove Wheels From Lift Truck
- Remove Solid Rubber Tire From Pneumatic Wheel
- Install Solid Rubber Tire on Pneumatic Wheel
- Wheels, Install
- Snap-On Tire, Change
- Remove Snap-On Solid Tire From Wheel
- Install Snap-On Solid Tire on Wheel
Adhesives and Sealants
Table 1. Maintenance Schedule
Capacities and Specifications
Counterweights
Steering System2 topics
- Specifications
- Turning Radius
Wheels and Tires
Capacities
Drift Rates (Maximum) for Tilt Cylinders
Mast Speeds4 topics
- Frame
- Drive Axle, Speed Reducer, and Differential E.200-3.20XM (E45-65
- Masts
- Hydraulic Pump and Fittings
Table 1. Manual Hydraulic Control Valve
Table 2. E-Hydraulic Control Valve
AC Motor Repair
Electro-Hydraulic Control Valve5 topics
- Electro-Hydraulic Control System
- Electro-Hydraulic Control Valve
- Electro-Hydraulic Valve Driver Module
- Mini-Lever Module (MLM)
- Joystick
Electro-Hydraulic Control Valve Repair9 topics
- Solenoid Coil Replacement
- Cartridge Replacement
- Electro-Hydraulic Pressure Reducing Valve (EHPR) Replacement
- Lift Circuit Check Valve Replacement
- Compensator Cartridge Replacement
- Primary and Secondary Relief Valves Replacement
- Tilt Counterbalance Valve Replacement
- Flow Regulator Valve Replacement
- E-Hydraulics Calibration
Mini-Lever Module17 topics
- Remove
- Install
- Mini-Lever Replacement
- Remove
- Clean and Inspect
- Install
- Push Button Switch Replacement
- Remove
- Install
- Test
- Mini-levers
- Full Stroke Test
- Function Returns to Neutral Test
- Push Button Switch
- Remove and Disassemble
- Inspect
- Assemble and Install
Table 1. Primary and Secondary Relief Valve Values
Table 2. Solenoid Resistance Values
Table 3. Cartridge and Solenoid Coil Nut Torque for Lift truck M
Table 4. Cartridge and Solenoid Coil Nut Torque for Lift truck M
Attachment
Repair35 topics
- Attachment
- Remove
- Install
- Sideshift Cylinder
- Remove
- Disassemble
- Inspect
- Assemble
- Install
- Fixed Frame
- Remove
- Disassemble
- Inspect
- Assemble
- Install
- Traverse Frame
- Remove
- Disassemble
- Inspect
- Assemble
- Install
- Boom
- Remove
- Disassemble
- Assemble
- Install
- Pivot Cylinders
- Remove
- Disassemble
- Inspect
- Assemble
- Install
- Fork Carriage
- Remove
- Install
Adjustments3 topics
- Cross-Over Relief Valves
- Rotate Speed
- Flow Requirements
Inside this manual
Real pages from this service manual (956 pages). Open the sample pages (PDF, 314 KB)
- Specifications, page 433: Steering Pressure Check
- Troubleshooting, page 545: AC Motor Controllers Status Code Charts
- Diagram, page 685: Diagrams, Schematics, or Arrangements
- Color page, page 915: Mini-Lever Module
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, 956 pages
Quantity one is the manual described above.
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