Hyster E30-35-40HSD2 (B219 B883) Forklift Service Manual

Format: PDF (Printable Document)
File Language: English
File Pages (Total): 3536
File Size (Total): 79.75 MB (Speed Download Link)
Brand: Hyster
Model: E30-35-40HSD2 (B219 B883) Forklift
Type of Document: Service Manual

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Hyster E30-35-40HSD2 (B219 B883) Forklift Service Manual

Hyster E30-35-40HSD2 (B219 B883) Forklift Index:

General
- Discharging the Capacitors
- Special Tools
Transaxle Assembly
- Remove Transaxle From Frame
- Remove the Parking Brake and Traction Motor
- Install Parking Brake and Traction Motor
- Install Transaxle to Frame
Maintenance and Repair
- Speed Sensor Repair
- Trunnion Cap Repair
- Fluid Level Check
- Fluid Change
- Breather Repair
- Stud Repair
- Input Seal Repair
- Cover to Housing Seal
  - During the Transaxle Warranty Period
  - After the Transaxle Warranty Period

General
- Discharging the Capacitors
- Special Tools
Transaxle Assembly
- Remove Transaxle From Frame
- Remove the Parking Brake and Traction Motor
- Install Parking Brake and Traction Motor
- Install Transaxle to Frame
Maintenance and Repair
- Speed Sensor Repair
- Trunnion Cap Repair
- Fluid Level Check
- Fluid Change
- Breather Repair
- Stud Repair
- Input Seal Repair
- Cover to Housing Seal
  - During the Transaxle Warranty Period
  - After the Transaxle Warranty Period

General
Safety Procedures When Working Near Mast
Fork Replacement
- Remove
- Install
- Checks
Carriages Repair
- Standard Carriage
  - Remove
  - Clean and Inspect
  - Install
- Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016
  - Remove
  - Disassemble
  - Clean and Inspect
  - Assemble
  - Install
- Integral Sideshift Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018
  - Remove
  - Disassemble
  - Clean and Inspect
  - Assemble
  - Install
- Integral Sideshift Carriage, Lift Trucks Manufactured Late June, 2018
  - Remove
  - Disassemble
  - Clean and Inspect
  - Assemble
  - Install
- Fork Positioner, Lift Trucks Manufactured Prior To December, 2016
  - Remove
  - Clean and Inspect
  - Disassemble and Assemble
  - Install
- Fork Positioner Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018
  - Remove
  - Clean and Inspect
  - Disassemble and Assemble
  - Install
  - Fork Positioner Hydraulic Hose Adjustment
- Fork Positioner Carriage, Lift Trucks Manufactured June, 2018 and After
  - Remove
  - Clean and Inspect
  - Disassemble and Assemble
  - Install
  - Fork Positioner Hydraulic Hose Adjustment
Two-Stage Mast With Limited Free-Lift Repair
- Remove
- Disassemble
- Clean and Inspect
- Assemble
- Install
- Header Hose Installation and Adjustment
  - Install
  - Adjust
Two-Stage Mast With Full Free-Lift Repair
- Remove
- Disassemble
- Clean and Inspect
- Assemble
- Install
- Header Hose Installation and Adjustment
  - Install
  - Adjust
Three-Stage Mast With Full Free-Lift Repair
- Remove
- Disassemble
- Clean and Inspect
- Assemble
- Install
- Header Hose Installation and Adjustment
  - Install
  - Adjust
Four-Stage Mast With Full Free-Lift Repair
- Remove
- Disassemble
- Clean and Inspect
- Assemble
- Install
- Header Hose Installation and Adjustment
Lift Chains Adjustment
Carriage Adjustments
Tilt Cylinders Adjustment
Mast Adjustments
- Load Roller, Adjust
- Mast Side Kicking, Adjust

General
Safety Procedures When Working Near Mast
Fork Replacement
- Remove
- Install
- Checks
Carriages Repair
- Standard Carriage
  - Remove
  - Clean and Inspect
  - Install
- Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016
  - Remove
  - Disassemble
  - Clean and Inspect
  - Assemble
  - Install
- Integral Sideshift Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018
  - Remove
  - Disassemble
  - Clean and Inspect
  - Assemble
  - Install
- Integral Sideshift Carriage, Lift Trucks Manufactured Late June, 2018
  - Remove
  - Disassemble
  - Clean and Inspect
  - Assemble
  - Install
- Fork Positioner, Lift Trucks Manufactured Prior To December, 2016
  - Remove
  - Clean and Inspect
  - Disassemble and Assemble
  - Install
- Fork Positioner Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018
  - Remove
  - Clean and Inspect
  - Disassemble and Assemble
  - Install
  - Fork Positioner Hydraulic Hose Adjustment
- Fork Positioner Carriage, Lift Trucks Manufactured June, 2018 and After
  - Remove
  - Clean and Inspect
  - Disassemble and Assemble
  - Install
  - Fork Positioner Hydraulic Hose Adjustment
Two-Stage Mast With Limited Free-Lift Repair
- Remove
- Disassemble
- Clean and Inspect
- Assemble
- Install
- Header Hose Installation and Adjustment
  - Install
  - Adjust
Two-Stage Mast With Full Free-Lift Repair
- Remove
- Disassemble
- Clean and Inspect
- Assemble
- Install
- Header Hose Installation and Adjustment
  - Install
  - Adjust
Three-Stage Mast With Full Free-Lift Repair
- Remove
- Disassemble
- Clean and Inspect
- Assemble
- Install
- Header Hose Installation and Adjustment
  - Install
  - Adjust
Four-Stage Mast With Full Free-Lift Repair
- Remove
- Disassemble
- Clean and Inspect
- Assemble
- Install
- Header Hose Installation and Adjustment
Lift Chains Adjustment
Carriage Adjustments
Tilt Cylinders Adjustment
Mast Adjustments
- Load Roller, Adjust
- Mast Side Kicking, Adjust

Safety Procedures When Working Near Mast
General
Description
Tilt Cylinder Repair for 1.0-2.0T Trucks
- Remove
- Disassemble
- Inspect
- Clean
- Assemble
- Install
- Tilt Cylinders, Adjust
- Tilt Cylinders Leak Check
Tilt Cylinder Repair for 2.0-5.5T Trucks
- Remove
- Disassemble
- Inspect
- Clean
- Assemble
- Install
- Tilt Cylinders, Adjust
- Tilt Cylinder Leak Check
Lift Cylinder Repair for Lift Truck Model J1.5XNT (K160)
- Main Lift Cylinder
  - Remove
  - Disassemble
  - Clean
  - Inspect
  - Assemble
  - Install
Lift Cylinder Repair for 1.5-2.0T Trucks
- Main Lift Cylinder
  - Remove
  - Disassemble
  - Clean
  - Inspect
  - Assemble
  - Install
Lift Cylinder Repair for 2.0-3.5T Trucks
- Main Lift Cylinders
  - Remove
  - Disassemble
  - Clean
  - Inspect
  - Assemble
  - Install
Lift Cylinder Repair for 4.0-5.5T Trucks
- Main Lift Cylinders
  - Remove
  - Disassemble
  - Clean
  - Inspect
  - Assemble
  - Install
Free Lift Cylinder Repair for Lift Truck Model J1.5XNT (K160)
- Free-Lift Cylinder
  - Remove
  - Disassemble
  - Clean
  - Inspect
  - Assemble
  - Install
Free Lift Cylinder Repair for 1.5-2.0T Trucks
- Free-Lift Cylinder
  - Remove
  - Disassemble
  - Clean
  - Inspect
  - Assemble
  - Install
Free-Lift Cylinder Repair for 2.0-3.5T Trucks
- Free-Lift Cylinder
  - Remove
  - Disassemble
  - Clean
  - Inspect
  - Assemble
  - Install
Free-Lift Cylinder Repair for 4.0-5.5T Trucks
- Free-Lift Cylinder
  - Remove
  - Disassemble
  - Clean
  - Inspect
  - Assemble
  - Install
Sideshift Cylinder Repair for 1.5-3.5T Trucks Prior to December 2016
- Remove
- Disassemble
- Clean and Inspect
- Assemble and Install
Sideshift Cylinder Repair for 1.5-3.5T Trucks After December 2016
- Remove
- Disassemble
- Clean and Inspect
- Assemble and Install
- Integral Side-Shift Cylinder Gland Leak Checks
Sideshift Cylinder Repair for 4.0-5.5T Trucks
- Remove
- Disassemble
- Clean and Inspect
- Assemble and Install
Fork Positioner Cylinder Repair Prior to December 2016
- Remove
- Disassemble
- Clean
- Inspect
- Assemble
- Install
  - Fork Positioner Cylinder Adjustment
Fork Positioner Cylinder Repair After December 2016
- Remove
- Disassemble
- Clean
- Inspect
- Assemble
- Install
  - Fork Positioner Cylinder Adjustment
Lift Cylinder Leak Check
Seal Kit Installation
- External Installation (Seal and Back-Up Ring)
- Internal Installation (Piston Rod Assembly)
Torque Specifications for Lift Truck Model J1.5XNT (K160)
- Tilt Cylinders
- Main and Free-Lift Cylinders
- Sideshift Cylinder
Torque Specifications for Lift Truck Models J1.6-2.0XNT (J30-40XNT) (K160), J1.6-2.0XN (J30-40XN) (A935), E30-40HSD2 (B219), and E30-40HSD3 (C219)
- Tilt Cylinders
- Main and Free-Lift Cylinders
- Sideshift Cylinder
- Fork Positioner Cylinder
Torque Specifications for Lift Truck Models E2.2-3.5XN (E45-70XN) (A268) and J2.2-3.5XN (J45-70XN) (A276)
- Tilt Cylinders
  - Piston Rod Nut
  - Gland
  - Tilt Cylinder Mounting Capscrew
  - Tilt Cylinder Rod End Capscrew
- Main and Free-Lift Cylinder
- Sideshift Cylinder
- Fork Positioner Cylinder
Torque Specifications for Lift Truck Model J4.0-5.0XN, J5.0-5.5XN6 (J80-120XN, J100XNL) (A970)
- Tilt Cylinders
- Main and Free-Lift Cylinder
- Sideshift Cylinder
Torque Specifications for Lift Truck Model E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
- Tilt Cylinder
- Main and Free Lift Cylinder
- Sideshift Cylinder