Hyster D210 Service & Repair Manual
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Hyster D210 Service & Repair Manual

Hyster D210 Service & Repair Manual

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Hyster D210 (V30ZMD) Forklift

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Summary of Contents for Hyster D210

  • Page 1 Hyster D210 (V30ZMD) Forklift...
  • Page 2 ELECTRICAL SYSTEM (TRUCKS WITH AC CONTROLLERS) J2.00-3.20XM (J40-65Z) [A416/B416]; V30ZMD [D210/E210]; E1.50-2.00XM (E25-35Z, E40ZS) [E114/F114]; E2.00-3.20XM (E45-65Z) [G108]; E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) [D098/E098] PART NO. 1534734 2200 SRM 1055...
  • Page 3 • Use the correct tools for the job. • Keep the tools clean and in good condition. • Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer. • Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.

  • Page 4: Table Of Contents

    Remove, Lift Truck Models J2.00-3.20XM (J40-65Z) (A416/B416) ............ Install, Lift Truck Models J2.00-3.20XM (J40-65Z) (A416/B416) ............Remove, Lift Truck Models E2.00-3.20XM (E45-65Z) (G108); V30ZMD (D210/E210); and E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114) ..................Install, Lift Truck Models E2.00-3.20XM (E45-65Z) (G108); V30ZMD (D210/E210); and E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114) ..................
  • Page 5 Lift Truck Models E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098) ....... Backup Alarm, Replace..........................Horn and Horn Button, Replace ........................Horn Replacement for Lift Trucks J2.0-3.20XM (J40-65Z) (A416/B416), V30ZMD (D210/E210), E1.5-2.0XM (E25.35Z, E40ZS) (E114/F114), and E2.00-3.20XM (E45-65Z) (G108) ......Horn Replacement for Lift Trucks E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098) ..
  • Page 6 Thanks very much for your reading, Want to get more information, Please click here, Then get the complete manual NOTE: If there is no response to click on the link above, please download the PDF document first, and then click on it. Have any questions please write to me: admin@servicemanualperfect.com...

  • Page 7: General

    2000 SRM 77 for lift truck models E3.50-5.50XL, tion. E4.50XLS (E70-120Z, E100ZS) (D098/E098). Fol- See the section AC Motor Repair 620 SRM lowing is a list of the switches: 1098 for lift truck models V30ZMD (D210/E210); • Lift - High Speed E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114);...

  • Page 8: Description

    Description 2200 SRM 1055 • Tilt - Low Speed • Fourth Auxiliary - Medium Speed • Third Auxiliary • Fourth Auxiliary - Low Speed Description FEATURES OF THE DISPLAY PANELS • Battery Discharge Indicator • Service Reminder (if enabled) NOTE: There are two dash display options, Standard •...

  • Page 9: Other Control Components

    E2.00-3.20XM (E45-65Z) (G108) key is in the ON position and the parking brake is and V30ZMD (D210/E210) the power supply for the not applied. The alarm is also activated if the key fans is located near the converter on the left fender is moved to the OFF position when the brake is not weldment and towards the front of the lift truck.

  • Page 10: Display Panel And Key Switch Replacement

    Display Panel and Key Switch Replacement 2200 SRM 1055 Display Panel and Key Switch Replacement DISPLAY PANEL, REPLACE has a malfunction. These Display Panels must be replaced as a unit. See Figure 2. WARNING 1. Disconnect the battery and discharge the capac- Before replacing the Display Panels, fully itors by holding the horn button down until the lower all parts of the mast and tilt it forward...
  • Page 11 2200 SRM 1055 Display Panel and Key Switch Replacement 1. DISPLAY PANEL 3. MOUNT NUT 2. MOUNT BRACKET 4. 8-PIN CONNECTOR Figure 2. Mounting of Display Panel...

  • Page 12: Key Switch, Replace

    Controller Replacement 2200 SRM 1055 KEY SWITCH, REPLACE 4. Remove the DO NOT CONNECT BATTERY tag from the truck battery connector and reconnect NOTE: The key switch is replaced as one of the the battery. components of the steering column. See the section Steering Wheel and Column Assembly Repair in the SRM Steering System for AC Electric Lift Trucks 1600 SRM 1054 for more information.
  • Page 13 6. FUSE 5 (40A) POWER STEERING Figure 4. AC Traction and Pump Motor Controllers (Gen V) (36v/48v or 72v/80v) for J2.00-3.20XM (J40-65Z) (A416) and E2.00-3.20XM (E45-65Z) (G108), Later Models Only and for J2.00-3.20XM (J40-65Z) (B416); E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114); and V30ZMD (D210/E210) Lift Truck Models...
  • Page 14 Figure 5. AC Traction Motor Controller and Contactor Control for DC Pump Motor (Gen V) (36v/48v or 72v/80v) for J2.00-3.20XM (J40-65Z) (A416) and E2.00-3.20XM (E45-65Z) (G108), Later Models Only and for J2.00-3.20XM (J40-65Z) (B416); E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114); and V30ZMD (D210/E210) Lift Truck Models...
  • Page 15 2200 SRM 1055 Controller Replacement 1. FUSE 7 (15A) AUXILIARY TERMINAL STRIP 7. AC TRACTION MOTOR CONTROLLER 2. FUSE 5 (15A) LIGHTS 8. AC PUMP MOTOR CONTROLLER 3. FUSE 3 (5A) KEYSWITCH 9. LED INDICATOR 4. POWER STEERING CONTACTOR 10. POSITIVE TEMPERATURE COEFFICIENT 5.
  • Page 16 Controller Replacement 2200 SRM 1055 1. FUSE 7 (15A) AUXILIARY TERMINAL STRIP 7. POSITIVE TEMPERATURE COEFFICIENT 2. FUSE 5 (15A) LIGHTS RESISTOR (PTC) 3. FUSE 3 (5A) KEYSWITCH 8. AC TRACTION MOTOR CONTROLLER 4. POWER STEERING CONTACTOR 9. FUSE 2 (325A) PUMP 5.
  • Page 17 2200 SRM 1055 Controller Replacement 1. FUSE 1 (15A) AUXILIARY TERMINAL STRIP 7. POSITIVE TEMPERATURE COEFFICIENT 2. FUSE 2 (15A) (SLOW BLOW) SEAT BRAKE RESISTOR (PTC) 3. FUSE 3 (15A) LIGHTS 8. AC TRACTION MOTOR CONTROLLER 4. FUSE 4 (5A) KEYSWITCH 9.

  • Page 18: Master Controller, Replace

    Controller Replacement 2200 SRM 1055 MASTER CONTROLLER, REPLACE 6. Disconnect the power supply cable from master controller. NOTE: If your lift truck is equipped with an Elec- tro-Hydraulic control valve, see Electro-Hydraulic 7. Remove three capscrews and master controller Control Valve 2000 SRM 1224 for the location and from mounting plate.
  • Page 19 2200 SRM 1055 Controller Replacement 1. MOUNTING PLATE 6. FAN COVER 2. SCREW 7. CAPSCREW 3. PLATE 8. GROMMET 4. FAN PLATE ASSEMBLY 9. MASTER CONTROLLER 5. POWER SUPPLY 10. COVER-COUNTERWEIGHT Figure 9. AC Master Controller for J2.00-3.20XM (J40-60Z) (A416/B416)

  • Page 20: Master Controller, Remove E1.50-2.00Xm (E25-35Z, E40Zs) (E114/F114); E2.00-3.20Xm (E45-65Z) (G108); And (V30Zmd) (D210/E210)

    See Figure 10. E2.00-3.20XM (E45-65Z) (G108); and NOTE: On the E2.00-3.20XM (E45-65Z) (G108) and (V30ZMD) (D210/E210) (V30ZMD) (D210/E210), the master controller is lo- 1. Install master controller on bracket with three cated on the left-hand side under the battery tray. capscrews.
  • Page 21 Controller Replacement 1. SCREW 6. WASHER 2. GUARD 7. LOCKWASHER 3. FAN 8. CAPSCREW 4. SPACER 9. MASTER CONTROLLER 5. HEAT SINK 10. BRACKET Figure 10. AC Master Controller for E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114); E2.00-3.20XM (E45-65Z) (G108); and V30ZMD (D210/E210)

  • Page 22: Master Controller, Remove E3.50-5.50Xl E4.50Xls (E70-120Z,E100Zs) (D098/E098)

    Controller Replacement 2200 SRM 1055 Master Controller, Remove E3.50-5.50XL 6. Remove three nuts and bolt and master con- troller from the master controller bracket, and E4.50XLS (E70-120Z,E100ZS) (D098/E098) fan bracket. NOTE: On the E3.50-5.50XL E4.50XLS (E70- Master Controller, Install E3.50-5.50XL 120Z,E100ZS) (D098/E098) lift truck model.

  • Page 23: Control Components Replacement

    2200 SRM 1055 Control Components Replacement Control Components Replacement GENERAL Prior to performing the replacement procedures in this section, it is advised that the technician perform adjustment procedures as appropriate if not already done. The various adjustment procedures may be found later in this manual.

  • Page 24: Brake Light Switch, Replace

    Control Components Replacement 2200 SRM 1055 BRAKE LIGHT SWITCH, REPLACE Legend for Figure 13 1. BRAKE PEDAL The brake light switch is a small switch fastened to 2. BRAKE LIGHT SWITCH the mount plate for the brake pedal assembly. This 3.

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