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Hyster C264 (N30ZDRS, N35-40ZRS N35ZDR, N45ZR N30ZDR, N35-40ZR) Service Manual – PDF DOWNLOAD
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Hyster C264 (N30ZDRS, N35-40ZRS N35ZDR, N45ZR N30ZDR, N35-40ZR) Service Manual – PDF DOWNLOAD
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Hyster C264 (N30ZDRS, N35-40ZRS N35ZDR, N45ZR N30ZDR, N35-40ZR) Service Manual – PDF DOWNLOAD
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Hyster C264 (N30ZDRS, N35-40ZRS N35ZDR, N45ZR N30ZDR, N35-40ZR) Service Manual – PDF DOWNLOAD
Language : English
Pages : 938
Downloadable : Yes
File Type : PDF
Size: 48.8 MB
TABLE OF CONTENTS:
Hyster C264 (N30ZDRS, N35-40ZRS N35ZDR, N45ZR N30ZDR, N35-40ZR) Service Manual – PDF DOWNLOAD
AC Motor Controllers Display Panel................................................ 1 toc............................................................................ 1 AC Motor Controllers/ Display Panel........................................ 1 Description................................................................ 4 General................................................................ 4 AC Motors.......................................................... 4 Motor Controllers.................................................. 4 Master Controller.................................................. 5 Dash Display....................................................... 5 Controller Area Network Bus (CANbus)............................... 5 AC Transistor Motor Controller Replacement................................. 6 General................................................................ 6 General Maintenance Instructions....................................... 8 Special Precautions................................................ 8 Fuses.................................................................. 9 Fan.................................................................... 9 Contactors............................................................. 9 Repair............................................................. 9 Master Controller Checks and Adjustments................................... 11 Function Settings.......................................................... 11 General................................................................ 11 Troubleshooting............................................................ 13 General................................................................ 13 Controller Status Light Emitting Diodes (LEDs)......................... 14 Master Controller.................................................. 14 AC Motor Controllers............................................... 14 Operator Status Messages............................................... 17 Status Codes........................................................... 21 Checking the Motor Controller.......................................... 93 Display Panel.............................................................. 93 General................................................................ 93 Premium Display Panel.............................................. 93 Standard Display Panel............................................. 94 Standard Display Functions and Features.................................... 95 Key-On Initialization.................................................. 95 Passwords.............................................................. 95 Performance Modes...................................................... 96 Battery Discharge Indicator (BDI)...................................... 96 Hourmeters............................................................. 96 Standard Dash Display Service Menu Navigation.............................. 97 General................................................................ 97 Moving Through Menu Selections......................................... 97 Editing and Adding Information......................................... 97 Access to Service Functions............................................ 98 Service Functions...................................................... 98 Premium Display Functions and Features.....................................100 Key-On Initialization..................................................100 Passwords..............................................................100 Operator Checklist Function............................................100 Performance Modes......................................................100 Battery Discharge Indicator............................................101 Hourmeters.............................................................101 Shelf Height Selector..................................................101 Premium Dash Display Service Menu Navigation...............................102 General................................................................102 Moving Through Menu Selections.........................................102 Access to Service Functions............................................103 Service Functions......................................................103 Connector Pin-Outs.........................................................105 System Logic Diagram.......................................................112 tables......................................................................... 1 Table 1. Factory Parameter Defaults........................................ 11 Table 2. Traction Parameter Defaults....................................... 12 Table 3. List of Operator Warning Messages................................. 17 Table 4. List of Fault Messages............................................ 21 Table 5. Password Prompt Screen............................................ 95 Table 6. Password Reminder Screen.......................................... 95 Table 7. Password Prompt Screen............................................ 97 Table 8. Password Prompt Screen............................................ 98 Table 9. Password Prompt Screen............................................100 Table 10. Password Screen..................................................100 Table 11. Password Prompt Screen...........................................102 Table 12. Password Prompt Screen...........................................103 AC Motor Repair....................................................................115 toc............................................................................115 AC Motor Repair............................................................115 General....................................................................117 Traction Motor Repair......................................................118 Disassemble............................................................118 Inspect................................................................118 Assemble...............................................................119 Drive End Bearing, Replace.............................................120 Hydraulic Motor Repair.....................................................121 Disassemble............................................................121 Inspect................................................................122 Assemble...............................................................123 Troubleshooting............................................................124 tables.........................................................................115 Table 1. Traction Motor Windings...........................................119 Table 2. Hydraulic Motor Windings..........................................123 Brake System.......................................................................126 toc............................................................................126 Brake System...............................................................126 Introduction...............................................................128 General................................................................128 Discharging the Capacitors.............................................128 Electric Brake.............................................................129 Air Gap................................................................130 Remove.................................................................131 Install................................................................131 Troubleshooting............................................................132 Capacities and Specifications......................................................135 toc............................................................................135 Capacities and Specifications..............................................135 Lubrication Specifications.................................................137 Oil Capacities.............................................................137 Hydraulic System...........................................................138 Lift Specifications........................................................139 Tire Sizes.................................................................144 Torque Specifications......................................................144 Master Drive Unit......................................................144 Reach Carriage.........................................................144 Mast...................................................................144 Hydraulic System ( N30-35ZDR and N35-40-45ZR ).........................145 Hydraulic System ( N30ZDRS and N35-40ZRS ).............................145 Steering System........................................................145 Load Wheels............................................................145 Fuses......................................................................145 Coil Resistance Values.....................................................146 Battery Specifications.....................................................147 Diagrams...........................................................................150 toc............................................................................150 Diagrams...................................................................150 Electrical System..................................................................185 toc............................................................................185 Electrical System..........................................................185 General....................................................................189 Discharging the Capacitors.............................................190 Static Strap...........................................................190 Inspect............................................................190 Replace............................................................190 Battery Connection.........................................................191 Inspect................................................................191 Replacing Cables.......................................................191 Key Switch.................................................................192 Replace................................................................192 Contactors.................................................................194 Function...............................................................194 Testing................................................................194 Remove.................................................................196 Install................................................................196 EE Contactors..........................................................196 Motor Controllers..........................................................198 Functions..............................................................198 Master Controller..................................................198 Steering Motor Controller..........................................198 Traction Motor Controller..........................................198 Lift Motor Controller..............................................198 Steer Caster Controller (Optional).................................198 Replace................................................................198 Traction and Lift Motor Controllers................................199 Master Controller..................................................199 Steering Controller................................................200 Steer Caster Controller (Option)...................................200 Integrated Fuse Board (IFB)................................................200 Fuses..................................................................201 Replace................................................................201 Power Disconnect Switch....................................................202 Replace................................................................202 Side-Stance Controls.......................................................204 Multifunction Control Handle...........................................204 Remove.................................................................205 Disassemble............................................................205 Assemble...............................................................207 Install................................................................207 Forward-Stance Controls....................................................208 Control Handle Functions...............................................208 Repair.............................................................208 Aft Travel Control Handle Option.......................................210 Repair.............................................................211 Steering Handle............................................................212 Steering Unit Repair...................................................212 Foot Switches..............................................................216 Brake Switch...........................................................216 Operator Sensing.......................................................216 Repair.................................................................216 Dash Display Assembly......................................................218 Description............................................................218 Remove.................................................................218 Test...................................................................219 Install................................................................219 Horn.......................................................................220 Audible Alarm..........................................................220 Light Assemblies...........................................................221 Front Lights...........................................................221 Bulb Replacement...................................................221 Assembly Replacement...............................................221 Rear Work and Caution Light............................................222 Rear Work Light....................................................222 Caution Light......................................................222 Light Switches.........................................................223 Cooling Fans...............................................................225 Electrical Compartment Fans............................................225 Replace............................................................226 Operator Fan...........................................................226 Repair.............................................................226 Impact Sensor..............................................................229 Remove.................................................................229 Install................................................................229 Height Proximity Switch....................................................230 Test...................................................................230 Remove.................................................................230 Install................................................................231 Adjust.................................................................231 Load Transport Proximity Switch............................................232 Replace................................................................232 Adjust.................................................................233 Fork Height Sensor Option..................................................233 Remove.................................................................233 Encoder Assembly...................................................233 Timing Belt........................................................234 Install................................................................235 Encoder Assembly...................................................235 Timing Belt........................................................236 Reach Position Sensor......................................................236 Remove.................................................................236 Install................................................................238 Retract Sensor.............................................................239 Remove.................................................................239 Install................................................................239 Tilt Leveling..............................................................241 Remove.................................................................241 Install................................................................241 Laser Option...............................................................242 Remove.................................................................242 Install................................................................242 Camera Option..............................................................243 Remove.................................................................243 Install................................................................243 Wiring Harness.............................................................244 Frame..............................................................................250 toc............................................................................250 Frame......................................................................250 General....................................................................252 Description................................................................252 Repairs - General..........................................................252 Welding................................................................253 Covers, Panels, and Plates.................................................253 Front Frame Panel (Left and Right).....................................253 Operator Compartment Cover.............................................254 Drive Unit Compartment Door............................................254 Door Pad...............................................................254 Operator Back Pad......................................................254 Side-Stance Models.................................................254 Forward-Stance Models..............................................254 Operator Front Pad.....................................................255 Caster Wheel Cover.....................................................255 Load Wheels................................................................255 Remove.................................................................255 Install................................................................255 Overhead Guard Replacement.................................................256 Remove.................................................................258 Install................................................................258 Front Lights...........................................................260 Bulb Replacement...................................................260 Assembly Replacement...............................................261 Rear Work and Caution Light........................................262 Caution Light......................................................262 Painting Instructions......................................................263 Safety Labels Replacement..................................................264 Hydraulic System...................................................................269 toc............................................................................269 Hydraulic System...........................................................269 General....................................................................272 Discharging the Capacitors.............................................273 Description................................................................274 Control Handle.............................................................274 Side-Stance Control Handle.............................................274 Forward-Stance.........................................................275 Maintenance................................................................276 Oil Level and Leaks....................................................276 Operation..............................................................276 Oil Change.............................................................276 Drain..............................................................276 Cylinder Identification............................................278 Fill...............................................................279 Main Lift Cylinders............................................279 Free-Lift Cylinders............................................280 Breather Cap...........................................................281 Inspect............................................................281 Oil Filter.............................................................281 Change.............................................................281 Oil Strainer...........................................................282 Check..............................................................282 Hydraulic System...........................................................282 General................................................................282 Cleaning...........................................................282 Noise Levels.......................................................282 Hoses..................................................................283 Fittings...............................................................285 Lift Pump and Motor........................................................285 Complete Unit..........................................................285 Remove.............................................................285 Install............................................................286 Lift Pump..............................................................288 Components.........................................................288 Pressure Flange Fitting........................................288 Supply and Return Fittings.....................................289 Manual Lowering Valve..........................................289 Pressure Test Ports............................................290 Pressure Transducer............................................290 Relief Valve...................................................292 Lowering Control Valve.........................................292 Remove Pump........................................................293 Install Pump.......................................................293 Auxiliary Hydraulics.......................................................294 Auxiliary Pump and Motor...............................................294 Remove.............................................................294 Disassemble........................................................295 Assemble...........................................................295 Install............................................................296 Front Selector Valve...................................................296 Rear Selector Valve....................................................297 Hydraulic Tank.............................................................299 Remove.................................................................299 Disassemble............................................................300 Breather Assembly..................................................300 Filter Assembly....................................................302 Low Oil Indicator Switch...........................................303 Tank Fittings......................................................303 Clean and Inspect......................................................303 Assemble...............................................................304 Breather Assembly..................................................304 Filter Assembly....................................................304 Low Oil Indicator Switch...........................................304 Tank Fittings......................................................304 Install................................................................304 Specifications.............................................................305 Troubleshooting............................................................306 tables.........................................................................269 Table 1. Main Lift Pump and Motor Configurations...........................274 Table 2. Cylinder Identification...........................................279 Industrial Battery.................................................................309 toc............................................................................309 Industrial Battery.........................................................309 General....................................................................311 Lead-Acid Batteries........................................................311 Specific Gravity...........................................................312 Chemical Reaction in a Cell................................................312 Electrical Terms...........................................................313 Battery Selection..........................................................314 Battery Voltage............................................................315 Battery as a Counterweight.................................................315 Battery Ratings............................................................316 Kilowatt-Hours.........................................................316 Battery Maintenance........................................................316 Safety Procedures......................................................316 Maintenance Records....................................................317 New Battery............................................................317 Cleaning Battery.......................................................317 Adding Water to Battery................................................319 Hydrometer.............................................................320 Battery Temperature....................................................320 Charging Battery.......................................................321 Types of Battery Charges...........................................322 Methods of Charging................................................323 Troubleshooting Charger............................................324 Knowing When Battery Is Fully Charged..............................324 Where to Charge Batteries..............................................324 Equipment Needed...................................................324 Battery Connectors.....................................................325 Battery Care...........................................................325 tables.........................................................................309 Table 1. Battery Capacity Terms............................................316 Lift Cylinders.....................................................................328 toc............................................................................328 Lift Cylinders.............................................................328 General....................................................................330 Description................................................................330 Lowering Control Valve.................................................331 Main Cylinder Repair.......................................................333 Disassemble............................................................333 Assemble...............................................................334 Free-Lift Cylinder Repair..................................................335 Disassemble............................................................335 Assemble...............................................................335 Troubleshooting............................................................337 Mast Description...................................................................339 toc............................................................................339 Mast.......................................................................339 General....................................................................341 Safety Procedures When Working Near Mast...................................343 Mast Weldments.............................................................344 Reach Carriage Assembly....................................................344 Three-Stage Mast...........................................................346 Description............................................................346 Operation..............................................................347 Mast Repair........................................................................350 toc............................................................................350 Mast.......................................................................350 General....................................................................353 Safety Procedures When Working Near Mast...................................353 Load Backrest..............................................................354 Remove.................................................................354 Install................................................................354 Forks......................................................................355 Remove.................................................................355 Install................................................................355 Checks.................................................................356 Sheaves....................................................................356 Hydraulic System...........................................................359 Hydraulic Oil..........................................................361 Drain..............................................................361 Cylinder Identification............................................362 Fill...............................................................364 Main Lift Cylinders............................................364 Free-Lift Cylinders............................................365 Reach Carriage Assembly....................................................366 Remove.................................................................366 Install................................................................367 Load Rollers...............................................................368 Mast...................................................................368 Reach Assembly.........................................................370 Load Rollers.......................................................370 Side Rollers.......................................................370 Mast.......................................................................371 Remove.................................................................371 Disassemble............................................................372 Clean and Inspect......................................................373 Assemble...............................................................375 Install................................................................376 Lift Cylinders.............................................................377 Main Lift Cylinders....................................................377 Remove.............................................................377 Install............................................................377 Free-Lift Cylinder.....................................................380 Remove.............................................................380 Install............................................................382 Lift Chains................................................................383 Clean and Inspect......................................................383 Mast Adjustments...........................................................384 General................................................................384 Mast Back Angle Adjustment.............................................384 Load Rollers Adjustment................................................385 Reach Carriage Assembly............................................385 Adjust Wear Plugs - Mast...............................................386 Adjust Main-Lift Chains................................................387 Adjust Free-Lift Chain.................................................387 Adjust Wear Strips.....................................................389 Mast Racking...........................................................390 Proximity Switches.....................................................392 Replace............................................................392 Free-Lift Proximity Switch.....................................392 Load Lowering Proximity Switch (Optional)......................393 Adjust.............................................................393 Mast Operation Check.......................................................393 Lift System Leak Check.....................................................394 Lift Cylinder Leak Check...............................................394 Tilt Cylinder Leak Check...............................................394 tables.........................................................................350 Table 1. Fork Tip Alignment................................................356 Table 2. Cylinder Identification...........................................363 Master Drive Unit..................................................................396 toc............................................................................396 Master Drive Unit..........................................................396 HFK400 Master Drive Unit...................................................398 General................................................................398 Description............................................................398 Drive Unit Maintenance and Repair......................................399 Remove.............................................................399 Install............................................................400 Disassemble........................................................401 Assemble...........................................................404 Troubleshooting........................................................412 GK Master Drive Unit.......................................................414 General................................................................414 Description............................................................414 Maintenance and Repair.................................................415 Install................................................................416 Assemble...............................................................416 Mounting Electric Motor............................................417 Pivoted Connection - Geared Steering...............................417 Disassemble............................................................417 Troubleshooting........................................................418 tables.........................................................................396 Table 1. Tooth Contact Pattern.............................................409 Metric and Inch (SAE) Fasteners....................................................421 toc............................................................................421 Metric and Inch (SAE) Fasteners............................................421 General....................................................................423 Threaded Fasteners.....................................................423 Nomenclature, Threads..................................................423 Strength Identification................................................424 Cotter (Split) Pins....................................................424 Fastener Torque Tables.................................................429 Conversion Table.......................................................431 tables.........................................................................421 Table 1. Bolts and Screws..................................................425 Table 2. Studs and Nuts....................................................426 Table 3. Torque Nuts.......................................................427 Table 4. Torque Nuts With Nylon Insert.....................................428 Table 5. Torque Values for Metric Fasteners*...............................429 Table 6. Torque Values for Inch Fasteners*.................................430 Table 7. Conversion Table for Metric and English Units.....................431 Table 8. Cotter Pin Dimensional Data.......................................432 Table 9. Cotter Pin Dimensional Data.......................................433 Table 10. Cotter Pin Dimensional Data......................................434 Table 11. Cotter Pin Dimensional Data......................................436 Periodic Maintenance...............................................................440 toc............................................................................440 Periodic Maintenance.......................................................440 General....................................................................443 Removing Covers........................................................443 Front Frame Panel (Left and Right).................................443 Operator Compartment Cover.........................................444 Drive Unit Compartment Door........................................445 Caster Wheel Cover.................................................445 Discharging the Capacitors.............................................445 How to Move Disabled Truck.............................................446 How to Tow Lift Truck..............................................446 How to Put Lift Truck on Blocks........................................447 How to Raise Load Wheels...........................................447 How to Raise the Drive Tire End....................................447 How to Raise the Entire Lift Truck.................................448 Manual Lowering Valve..................................................449 N30-35ZDR and N35-40-45ZR .........................................449 N30ZDRS and N35-40ZRS .............................................449 Transporting...............................................................450 Loading................................................................450 Unloading..............................................................450 Preparation for Use........................................................451 Preparation After Shipment.............................................451 Preparation After Storage..............................................451 Safety Procedures When Working Near Mast...................................451 Maintenance Schedule.......................................................452 Maintenance Procedures Every 8 Hours or Daily..............................456 Checks With Key Switch Turned OFF......................................456 Battery............................................................456 Tires and Wheels...................................................457 Frame and Load Wheels..............................................457 Safety Labels......................................................458 Overhead Guard.....................................................458 Forks Check........................................................458 Lift Chain Check...................................................459 Mast Check.........................................................460 Reach, Tilt, and Sideshift.........................................460 Checks With Key Switch Turned ON.......................................460 Operation..........................................................460 Hydraulic System...................................................461 Dash Display.......................................................461 Lift System Operation..............................................462 Multifunction Control Handle.......................................463 Brake..............................................................463 Steering System....................................................464 Maintenance Procedures Every 500 Hours or 3 Months.........................464 Master Drive Unit......................................................464 Hydraulic System.......................................................464 Hydraulic Filter Element Change........................................466 Caster Adjustment......................................................466 Elastomer Spring Type Adjustment...................................466 Belleville Spring Type Adjustment..................................468 Spring Pack Replacement............................................469 Remove Spring Assembly.........................................469 Replace Spring Pack............................................470 Install Spring Assembly........................................470 Drive Tire Check.......................................................470 Lift System Operation..................................................471 Forks..............................................................471 Mast...............................................................471 Lift Chains........................................................471 Other Lubrication......................................................471 Maintenance Procedures Every 2000 Hours or Yearly..........................472 Brakes.................................................................472 Check..............................................................472 Electric System........................................................472 Main Contactor.....................................................472 Inspect........................................................472 Hydraulic System.......................................................473 Drain..............................................................473 Cylinder Identification........................................474 Fill...............................................................476 Main Lift Cylinders............................................476 Free-Lift Cylinders............................................477 Hydraulic Filter Change............................................478 Check Hydraulic Strainer...........................................478 Lift and Tilt System Leaks Check...........................................479 Lift System............................................................479 Tilt System............................................................479 Battery Maintenance........................................................480 How to Charge Battery..................................................480 How to Change Battery..................................................481 Tires and Wheels...........................................................484 Drive Tire.............................................................484 How to Change Drive Tire...............................................484 Tandem Load Wheels.....................................................485 Caster Wheels..........................................................485 Remove.............................................................485 Install............................................................486 Preparation for Storage....................................................487 Short-Term Storage (1 to 6 months).....................................487 Long-Term Storage (6 months or longer).................................487 tables.........................................................................440 Table 1. Maintenance Schedule..............................................453 Table 2. Fork Tip Alignment................................................458 Table 3. Hydraulic Tank Capacities.........................................465 Table 4. Caster Specifications.............................................467 Table 5. Upper Adjustment Gap Measurement..................................469 Table 6. Free-Lift Cylinder Rod Widths.....................................475 Table 7. Battery Size Specifications.......................................483 Table 8. Tires and Wheels..................................................484 Reach Carriages....................................................................490 toc............................................................................490 Reach Carriages............................................................490 General....................................................................493 Safety Procedures When Working Near Mast...................................493 Description................................................................494 Repair - General...........................................................496 Load Backrest..............................................................496 Remove.................................................................496 Install................................................................496 Forks......................................................................497 Replacement............................................................497 Remove.............................................................497 Install............................................................497 Reach Carriage Assembly....................................................498 Remove.................................................................498 Inspect................................................................499 Install................................................................499 Reach Carriage Assembly Repair.............................................501 Load Rollers Repair........................................................501 Side Rollers Repair (6.9 Mast Only) (N30ZDRS and N35-40ZRS)................502 Reach Assembly Front Frame.................................................503 Remove.................................................................503 Disassemble (With Sideshift)...........................................504 Disassemble (Without Sideshift)........................................506 Clean and Inspect......................................................507 Assemble (With Sideshift)..............................................507 Assemble (Without Sideshift)...........................................507 Install................................................................507 Single-Reach Scissor Arms..................................................508 Remove and Disassemble.................................................508 Clean and Inspect......................................................511 Assemble and Install...................................................511 Double-Reach Scissor Arms..................................................513 Disassemble............................................................513 Clean and Inspect......................................................516 Assemble...............................................................516 Rear Frame Assembly........................................................518 Remove.................................................................518 Disassemble............................................................520 Clean and Inspect......................................................521 Assemble...............................................................521 Install................................................................521 Reach Cylinders............................................................522 Remove.................................................................522 Disassemble............................................................524 Clean and Inspect......................................................524 Assemble...............................................................525 Install................................................................525 Tilt Cylinder..............................................................526 Remove.................................................................526 Clean, Inspect, and Repair.............................................526 Install................................................................526 Sideshift Cylinder.........................................................528 Repair.................................................................528 Front Selector Valve.......................................................529 Rear Selector Valve........................................................530 Reach Assembly Adjustments.................................................531 Check Adjustment.......................................................531 Adjust Side Rollers and Load Rollers...................................532 Adjust Reach Cylinders.................................................533 Lift Chains................................................................534 Inspect................................................................534 Clean and Lubricate....................................................535 Adjust Main-Lift Chains................................................535 Adjust Free-Lift Chains................................................535 Specifications.............................................................537 Troubleshooting ...........................................................540 tables.........................................................................490 Table 1. General Specifications............................................537 Table 2. Operating Times ..................................................538 Steering System....................................................................544 toc............................................................................544 Steering System............................................................544 General....................................................................547 Discharging the Capacitors.............................................548 Raising the Lift Truck.................................................549 How to Raise the Drive Tire End....................................549 How to Raise the Entire Lift Truck.................................550 Description................................................................550 Steering Handle Assembly...................................................553 Fixed Handle...........................................................553 Description........................................................553 Remove.............................................................553 Disassemble........................................................553 Assemble...........................................................556 Install............................................................556 Adjustable Handle......................................................557 Description........................................................557 Remove.............................................................557 Disassemble........................................................557 Assemble...........................................................561 Install............................................................561 Steering Controller........................................................562 Description............................................................562 Remove.................................................................562 Disassemble............................................................563 Assemble...............................................................563 Install................................................................563 Steering Proximity Switch..................................................563 Replace................................................................563 Steering Motor.............................................................564 Description............................................................564 Remove.................................................................564 Disassemble............................................................565 Assemble...............................................................565 Install................................................................565 Caster Assembly - General..................................................566 Caster Adjustment......................................................566 Elastomer Spring Type Adjustment...................................566 Belleville Spring Type Adjustment..................................568 Spring Pack Replacement............................................569 Remove Spring Assembly.........................................569 Replace Spring Pack............................................570 Install Spring Assembly........................................570 Caster Wheels..............................................................571 Remove.................................................................571 Install................................................................572 Caster Wheel Assembly (Nonsteered).........................................572 Description............................................................572 Remove.................................................................572 Disassemble............................................................574 Upper and Lower Support Housings...................................574 Spring Assembly From Lower Support Assembly........................574 Caster Spindle From Lower Support..................................574 Caster Wheels......................................................575 Lower Support Housing..............................................576 Upper Support Housing..............................................577 Assemble...............................................................577 Upper Support Housing..............................................577 Lower Support Housing..............................................578 Caster Wheels......................................................579 Caster Spindle to Lower Support....................................579 Spring Assembly to Lower Support...................................579 Upper and Lower Support Housings...................................579 Install................................................................580 Caster Assembly (Steered)..................................................581 Description............................................................581 Remove.................................................................581 Disassemble............................................................583 Upper and Lower Support............................................583 Spring Assembly From Lower Support Housing.........................583 Caster Spindle From Lower Support..................................584 Caster Wheels......................................................584 Lower Support Housing..............................................585 Upper Support Housing..............................................586 Caster Steering Motor..............................................587 Assemble...............................................................588 Caster Steering Motor..............................................588 Upper Support Housing..............................................588 Lower Support Housing..............................................589 Caster Wheels......................................................590 Caster Spindle to Lower Support....................................590 Spring Assembly to Lower Support...................................591 Upper and Lower Support Housings...................................591 Install................................................................591 Troubleshooting............................................................592 tables.........................................................................544 Table 1. Caster Specifications.............................................567 Table 2. Upper Adjustment Gap Measurement..................................569 Troubleshooting and Adjustments Using the AC Controls Program (ETACC)..............594 toc............................................................................594 Troubleshooting and Adjustments Using the AC Controls Program (E...........594 General....................................................................597 Computer Requirements..................................................597 Software, Install......................................................597 Language Selection.....................................................597 Demo Mode..............................................................598 Connect PC to Lift Truck...............................................602 Starting AC Controls Program...........................................604 Lift Truck Control Setup...................................................608 Change Lift Truck Serial Number or Hourmeter...........................608 Setting Factory Default Values or Changing Lift Truck Parameters.......610 Create New Custom Lift Truck Configuration.............................616 Lift Truck Configuration Properties....................................619 Import New Lift Truck Configuration From Disk..........................622 Delete Custom Lift Truck Configuration or Password File................624 Dash Display...............................................................627 Custom Display Languages...............................................627 Download Display Language..............................................629 Clear Operator Log.....................................................629 Password Functions.........................................................632 Enable/Disable Password and Lift Truck Inspection Functions............632 Truck Inspection Checklist.........................................632 Password...........................................................632 Password Properties....................................................632 Create New Password File...............................................637 Download Passwords.....................................................639 Upload Passwords.......................................................639 Reports Menu...............................................................643 Devices Report.........................................................643 Custom Report..........................................................643 Password Report........................................................643 Operator Report........................................................650 Current Settings Report................................................653 Status Code Report.....................................................656 Status Codes Log.......................................................659 Troubleshooting............................................................661 Diagnostics............................................................661 Help Menu..................................................................664 General................................................................664 Contents...............................................................664 Technical Support......................................................664 About Electric Truck AC Controls Program...............................664 User Interface (2).................................................................670 toc............................................................................670 User Interface.............................................................670 General....................................................................673 Description............................................................673 Dash Display Menu Access...............................................673 Menu Navigation............................................................674 Standard Display.......................................................674 Main Menu..................................................................674 Diagnostics Menu...........................................................674 Static Diagnostics.....................................................674 Traction System........................................................678 Hydraulic System.......................................................679 Steer System...........................................................682 General Truck..........................................................683 Error Log..............................................................684 View Hourmeters............................................................684 Truck Hours............................................................684 Traction Hours.........................................................685 Pump Hours.............................................................685 Auxiliary Hours........................................................686 Setup Menu.................................................................686 Lift Settings..........................................................687 Lift Maximum Speed ( N35ZDR, N45ZR, N30ZDR, N35-40ZR ).............687 Lower Maximum Speed ( N35ZDR, N45ZR, N30ZDR, N35-40ZR )............687 Auxiliary Settings.....................................................688 Fast Extend Speed..................................................688 Slow Extend Speed..................................................688 Fast Retract Speed.................................................689 Slow Retract Speed.................................................689 Tilt Up Speed......................................................690 Tilt Down Speed....................................................690 Sideshift Speed....................................................691 Reach Cushioning...................................................691 Steer Settings.........................................................692 Steer Mode.........................................................692 Steer Effort.......................................................692 Steer Ratio........................................................693 Truck Settings.........................................................693 Truck Serial Number................................................693 Truck Voltage......................................................694 Truck Capacity.....................................................694 Battery Type.......................................................695 BDI Adjust Calibration.............................................695 Extended Shift.....................................................696 Lift Limit Without Override ( N35ZDR, N45ZR, N30ZDR, N35-40ZR )....696 Lift Limit With Override ( N35ZDR, N45ZR, N30ZDR, N35-40ZR ).......697 Audible Alarm......................................................697 Visible Alarm......................................................698 Autotilt Option....................................................699 Laser Option.......................................................699 Carry Level Option.................................................700 Slow Extended......................................................700 Simultaneous Hydraulics............................................701 Password Option....................................................701 Shutdown Timeout...................................................702 Traction Settings......................................................702 Rabbit Speed.......................................................702 Rabbit Acceleration................................................703 High Speed.........................................................703 High Acceleration..................................................704 Mid Speed..........................................................704 Mid Acceleration...................................................705 Turtle Speed.......................................................705 Turtle Acceleration................................................706 Neutral Braking....................................................706 Plug Braking.......................................................707 View Software Versions.....................................................707 Master Controller......................................................707 Display................................................................708 Traction Controller....................................................708 Hydraulic Controller...................................................709 Control Handle.........................................................709 Remote CAN Module ( N35ZDR, N45ZR, N30ZDR, N35-40ZR )..................710 Steer Controller.......................................................710 Caster Controller......................................................711 Aux Pump...............................................................711 Impact Sensor..............................................................712 Functions..............................................................712 Functions..............................................................713 Impact Action......................................................713 Impact Sound.......................................................713 Clear Impact.......................................................713 Hard Duration......................................................713 Hard Acceleration..................................................713 Soft Duration......................................................713 Sort Acceleration..................................................713 Impact Events......................................................713 Password Menu..............................................................714 Add Password...........................................................715 Delete Password........................................................716 Edit Password..........................................................717 tables.........................................................................670 Table 1. Password Screen...................................................673 Table 2. Static Diagnostics Menu...........................................675 Table 3. Traction System Diagnostics Menu..................................678 Table 4. Hydraulic System Diagnostics Menu.................................679 Table 5. Steering System Diagnostics Menu..................................682 Table 6. General Truck Diagnostics Menu....................................683 Table 7. Error Log.........................................................684 Table 8. Truck Hours.......................................................684 Table 9. Traction Hours....................................................685 Table 10. Pump Hours.......................................................685 Table 11. Auxiliary Hours..................................................686 Table 12. Lift Maximum Speed Menu..........................................687 Table 13. Lower Maximum Speed Menu.........................................687 Table 14. Fast Extend Speed Menu...........................................688 Table 15. Slow Extend Speed Menu...........................................688 Table 16. Fast Retract Speed Menu..........................................689 Table 17. Slow Retract Speed Menu..........................................689 Table 18. Tilt Up Speed Menu...............................................690 Table 19. Tilt Down Speed Menu.............................................690 Table 20. Sideshift Speed Menu.............................................691 Table 21. Cushioning Speed Menu............................................691 Table 22. Steer Mode Menu..................................................692 Table 23. Steer Effort Menu................................................692 Table 24. Steer Ratio Menu.................................................693 Table 25. Truck Serial Number Menu.........................................693 Table 26. Truck Voltage Menu...............................................694 Table 27. Truck Capacity Menu..............................................694 Table 28. Truck Type Menu..................................................695 Table 29. BDI Adjust Calibration Menu......................................695 Table 30. Extended Shift Menu..............................................696 Table 31. Lift Limit Without Override......................................696 Table 32. Lift Limit With Override.........................................697 Table 33. Audible Alarm Menu...............................................697 Table 34. Visible Light Alarm Menu.........................................698 Table 35. Autotilt Option Menu.............................................699 Table 36. Laser Option.....................................................699 Table 37. Carry Level Option Menu..........................................700 Table 38. Restore Defaults Menu............................................700 Table 39. Simultaneous Hydraulics Menu.....................................701 Table 40. Password Option Menu.............................................701 Table 41. Shutdown Timeout Menu............................................702 Table 42. Rabbit Speed Menu................................................702 Table 43. Rabbit Acceleration Menu.........................................703 Table 44. High Speed Menu..................................................703 Table 45. High Acceleration Menu...........................................704 Table 46. Mid Speed Menu...................................................704 Table 47. Mid Acceleration Menu............................................705 Table 48. Turtle Speed Menu................................................705 Table 49. Turtle Acceleration Menu.........................................706 Table 50. Neutral Braking Menu.............................................706 Table 51. Plug Braking Menu................................................707 Table 52. Master Controller Software Version...............................707 Table 53. Display Software Version.........................................708 Table 54. Traction Controller Software Version.............................708 Table 55. Hydraulic Controller Software Version............................709 Table 56. Control Handle Software Version..................................709 Table 57. Remote CAN Module Software Version...............................710 Table 58. Steer Controller Software Version................................710 Table 59. Caster Controller Software Version...............................711 Table 60. Aux Pump Controller Software Version.............................711 Table 61. Impact Sensor Data Display.......................................712 User Interface (3).................................................................720 toc............................................................................720 User Interface.............................................................720 General....................................................................723 Description............................................................723 Dash Display Menu Access...............................................723 Menu Navigation............................................................724 Main Menu..................................................................724 Diagnostics Menu...........................................................724 Static Diagnostics.....................................................724 Traction System........................................................726 Hydraulic System.......................................................726 Steer System...........................................................727 Error Log..............................................................728 View Hourmeters............................................................729 Truck..................................................................729 Traction...............................................................729 Pump...................................................................729 Auxiliary..............................................................729 Setup Menu.................................................................730 Display Settings.......................................................730 Display Language...................................................730 Year, Month, Date, Hour, Minute, and Second........................730 View Software Versions.....................................................731 Master Controller......................................................731 Display................................................................731 Traction Controller....................................................731 Hydraulic Controller...................................................731 Control Handle.........................................................731 Remote CAN Module ( N35ZDR, N45ZR, N30ZDR, N35-40ZR Only)..............731 Steer Controller.......................................................731 Caster Controller......................................................732 Aux Pump...............................................................732 Passwords Menu.............................................................732 View Operator Log......................................................732 Add Password...........................................................734 Delete Password........................................................735 Edit Password..........................................................736 Setup Shelf Height.........................................................737 Learn Shelf Height.........................................................737 Impact Sensor..............................................................738 Functions..............................................................739 Impact Action......................................................739 Impact Sound.......................................................739 Clear Impact.......................................................739 Hard Duration......................................................739 Hard Acceleration..................................................739 Soft Duration......................................................740 Soft Acceleration..................................................740 Impact Events......................................................740 Maintenance Reminder.......................................................740 Functions..............................................................741 Maintenance Reminder...............................................741 Maintenance Interval...............................................741 tables.........................................................................720 Table 1. Enter Password Screen.............................................723 Table 2. Static Diagnostics Menu...........................................725 Table 3. Traction System Menu..............................................726 Table 4. Hydraulic System Menu.............................................726 Table 5. Steer System Menu.................................................727 Table 6. Impact Sensor Data Display........................................738 User Interface (4).................................................................744 toc............................................................................744 User Interface.............................................................744 General....................................................................748 Description............................................................748 Dash Display Menu Access...............................................748 Menu Navigation............................................................749 Main Menu..................................................................749 Diagnostics Menu...........................................................749 Static Diagnostics.....................................................749 Traction System........................................................751 Hydraulic System.......................................................751 Steer System...........................................................752 General Truck..........................................................753 Height Sensor......................................................753 Calibrate Fork Tare Down...........................................753 Calibrate Fork Tare Up.............................................753 Calibrate Cushion Inpoint ( N35ZDR, N45ZR, N30ZDR, N35-40ZR )......753 Calibrate Cushion Outpoint ( N35ZDR, N45ZR, N30ZDR, N35-40ZR ).....753 Calibrate Mast Slowdown............................................753 Error Log..............................................................754 View Hourmeters............................................................755 Truck..................................................................755 Traction...............................................................755 Pump...................................................................755 Auxiliary..............................................................755 Setup Menu.................................................................756 Lift Settings..........................................................757 Lift Maximum Speed ( N35ZDR, N45ZR, N30ZDR, N35-40ZR ).............757 Lower Maximum Speed ( N35ZDR, N45ZR, N30ZDR, N35-40ZR )............757 Lift Acceleration..................................................757 Auxiliary Settings.....................................................758 Fast Extend Speed..................................................758 Slow Extend Speed..................................................758 Fast Retract Speed.................................................758 Slow Retract Speed.................................................759 Tilt Up Speed......................................................759 Tilt Down Speed....................................................759 Sideshift Speed....................................................759 Reach Cushioning...................................................759 Steer Settings.........................................................760 Steer Mode.........................................................760 Steer Effort.......................................................760 Steer Ratio........................................................760 Display Settings.......................................................761 Display Language...................................................761 Year, Month, Date, Hour, Minute, and Second........................761 Truck Settings.........................................................761 Serial Number......................................................762 Voltage............................................................762 Capacity Lbs.......................................................762 Battery Type.......................................................762 BDI Adjust Calibration.............................................762 Extended Shift.....................................................762 Shelf Height Selection.............................................763 Load Weight Option ( N35ZDR, N45ZR, N30ZDR, N35-40ZR ).............763 Lift Limit Without Override ( N35ZDR, N45ZR, N30ZDR, N35-40ZR )....763 Lift Limit With Override...........................................763 Audible Alarm......................................................763 Visible Alarm Option...............................................764 Fork Height Display................................................764 Auto Tilt Option...................................................764 Laser Option.......................................................764 Carry Level Option.................................................764 Slow Extended......................................................764 Simultaneous Hydraulics............................................764 Password Option....................................................764 Shutdown Timeout...................................................764 Truck Inspection...................................................764 Traction Settings......................................................765 Rabbit Speed.......................................................765 Rabbit Acceleration................................................765 High Speed.........................................................765 High Acceleration..................................................765 Mid Speed..........................................................766 Mid Acceleration...................................................766 Turtle Speed.......................................................766 Turtle Acceleration................................................766 Neutral Braking....................................................766 Plug Braking.......................................................766 View Software Versions.....................................................766 Master Controller......................................................766 Display................................................................766 Traction Controller....................................................766 Hydraulic Controller...................................................766 Control Handle.........................................................766 Remote CAN Module ( N35ZDR, N45ZR, N30ZDR, N35-40ZR )..................767 Steer Controller.......................................................767 Caster Controller......................................................767 Aux Pump...............................................................767 Passwords Menu.............................................................768 Functions..............................................................769 View Operator Log..................................................769 Add Password.......................................................770 Delete Password....................................................771 Edit Password......................................................771 Setup Shelf Height.........................................................772 Learn Shelf Height.........................................................773 Impact Sensor..............................................................773 Functions..............................................................775 Impact Action......................................................775 Impact Sound.......................................................775 Clear Impact.......................................................775 Hard Duration......................................................775 Hard Acceleration..................................................775 Soft Duration......................................................775 Soft Acceleration..................................................775 Impact Events......................................................775 Maintenance Reminder.......................................................776 Functions..............................................................776 Maintenance Reminder...............................................776 Maintenance Interval...............................................776 tables.........................................................................744 Table 1. Enter Password Screen.............................................748 Table 2. Static Diagnostics Menu...........................................750 Table 3. Traction System Menu..............................................751 Table 4. Hydraulic System Menu.............................................751 Table 5. Steer System Menu.................................................752 Table 6. General Truck Menu................................................753 Table 7. Impact Sensor Data Display........................................774 User Interface.....................................................................779 toc............................................................................779 User Interface.............................................................779 General....................................................................781 Description............................................................781 Dash Display Menu Access...............................................781 Menu Navigation............................................................782 Standard Display.......................................................782 Main Menu..................................................................782 Diagnostics Menu...........................................................783 Static Diagnostics.....................................................783 Traction System........................................................787 Hydraulic System.......................................................788 Steer System...........................................................791 Error Log..............................................................792 View Hourmeters............................................................792 View Software Versions.....................................................792 Master Controller......................................................792 Display................................................................793 Traction Controller....................................................793 Hydraulic Controller...................................................794 Control Handle.........................................................794 Remote CAN Module ( N35ZDR, N45ZR, N30ZDR, N35-40ZR )..................795 Steer Controller.......................................................795 Caster Controller......................................................796 Aux Pump...............................................................796 Impact Sensor..............................................................797 Functions..............................................................798 Impact Action......................................................798 Impact Sound.......................................................798 Clear Impact.......................................................798 Hard Duration......................................................798 Hard Acceleration..................................................798 Soft Duration......................................................798 Soft Acceleration..................................................799 Impact Events......................................................799 Passwords Menu.............................................................799 Add Password...........................................................800 Delete Password........................................................801 Edit Password..........................................................802 tables.........................................................................779 Table 1. Static Diagnostics Menu...........................................783 Table 2. Traction System Diagnostics Menu..................................787 Table 3. Hydraulic System Diagnostics Menu.................................788 Table 4. Steering System Diagnostics Menu..................................791 Table 5. Error Log.........................................................792 Table 6. Master Controller Software Version................................792 Table 7. Display Software Version..........................................793 Table 8. Traction Controller Software Version..............................793 Table 9. Hydraulic Controller Software Version.............................794 Table 10. Control Handle Software Version..................................794 Table 11. Remote CAN Module Software Version...............................795 Table 12. Steer Controller Software Version................................795 Table 13. Caster Controller Software Version...............................796 Table 14. Aux Pump Controller Software Version.............................796 Table 15. Impact Sensor Data Display.......................................797 Wire Harness Repair................................................................804 toc............................................................................804 Wire Harness Repair........................................................804 General....................................................................808 Deutsch Crimping Tool......................................................808 How to Strip a Wire for Use With Deutsch Crimping Tool.................808 How to Crimp With the Deutsch Crimping Tool............................809 Calibration Test for the Deutsch Crimping Tool.........................810 Deutsch Connectors.........................................................812 DT, DTM, and DTP Series Connectors.....................................812 Connector Receptacle Replacement...................................820 Connector Plug Replacement.........................................825 Connector Receptacle Pin Replacement...............................831 Connector Plug Socket Replacement..................................837 HD Series Connectors...................................................845 Connector Receptacle Replacement...................................847 Connector Plug Replacement.........................................850 Connector Receptacle Pin Replacement...............................853 Connector Plug Socket Replacement..................................858 Sealing Plugs..........................................................862 Metri-Pack Connectors......................................................864 Remove and Install.....................................................864 Micro-Pack Connectors......................................................866 Weather-Pack Connectors....................................................867 Weather-Pack Terminal Repair...........................................867 AMPSEAL Crimping Tools.....................................................868 AMP Hand Crimping Tool With Certi-Crimp................................868 Description........................................................868 Stripping Wire for Use With AMP Hand Crimping Tool.................869 Insulation Crimp Adjustment........................................869 Maintenance and Inspection for AMP Hand Crimping Tool..............870 AMP Hand Crimping Tool.........................................870 Crimp Height Inspection........................................870 How to Use AMP Hand Crimping Tool......................................871 AMP Pro-Crimper II Tool................................................871 Description........................................................871 Remove and Install Die Set and Locator Assembly................872 Stripping Wire for Use With AMP PRO-CRIMPER II Tool................873 Contact Support Adjustment.........................................873 Crimp Height Adjustment............................................874 Maintenance and Inspection Procedures..............................874 PRO-CRIMPER II Tool............................................874 Crimp Height Inspection........................................874 How to Use AMP PRO-CRIMPER II Tool.....................................875 AMPSEAL Connector Assemblies...............................................876 Description for Plug Connector Assembly................................876 Seal Plug..........................................................876 Contact Crimping...................................................877 Contact Removal....................................................877 Contact Insertion..................................................879 Description for Plug Connector and Header Assembly.....................881 Voltage Reading....................................................882 Seal Plug..........................................................882 Contact Crimping...................................................883 Contact Removal....................................................885 Contact Insertion..................................................887 AMP Superseal 1.5 Crimping Tools...........................................889 Mini Mic Receptacle and Tab Contacts...................................889 Description........................................................889 Crimping Conditions and Measurements...............................889 Insertion of Rubber Seal on Cable..................................891 Correction or Replacement of Parts.................................892 AMP Hand Application Tool..............................................896 Description........................................................896 Maintenance and Inspection.........................................896 Crimp Height Inspection........................................896 Crimp Height Adjustment............................................897 How to Use AMP Hand Application Tool...................................897 AMP Pro-Crimper II Tool................................................898 Description........................................................898 Remove and Install Die Set and Locator Assembly................898 Adjustments........................................................899 Contact Support................................................899 Crimp Height...................................................899 Inspections and Maintenance........................................901 Crimp Height Inspection........................................901 Visual Inspection..............................................901 Maintenance....................................................901 How to Use Pro-Crimper II Tool.........................................901 AMP Superseal 1.5 Connector Assemblies.....................................902 Description............................................................902 Harness Assembly...................................................902 Positioning of anti-backout device.............................903 Removal of Contacts............................................905 Repair and Maintenance.................................................909 Panel Mount Option.....................................................909 AMP Fastin-Faston Hand Tools...............................................909 Description - AMP Double Action Hand Tool..............................909 Maintenance and Inspection Procedures..................................911 Daily Maintenance..................................................911 Periodic Tool Inspection...........................................911 Lubrication....................................................911 Visual Inspection..............................................911 Crimp Height Inspection............................................912 Certi-Crimp Ratchet Inspection.....................................912 How to Use AMP Double Action Hand Tool.................................913 Description - AMP Extraction Tool......................................914 Maintenance and Inspection.............................................914 How to Use AMP Extraction Tool.........................................915 AMP Fastin-Faston Receptacles and Housings.................................916 Description............................................................916 Wire Repair................................................................922 Wire Splicing Requirements.............................................922 Deutsch Jiffy Splice...................................................923 Assemble...........................................................923 Disassemble........................................................925 Del-City Crimp-Solder-Shrink Splice....................................927 Twisted/Shielded Cable and Leads Repair....................................928 Twisted/Shielded Cable Repair..........................................928 Twisted Leads Repair...................................................930 Special Tools..............................................................931 tables.........................................................................804 Table 1. Wire Strip Length Specifications..................................809 Table 2. Wire Size (AWG)...................................................870 Table 3. Crimp Height......................................................871 Table 4. Strip Length for PRO-CRIMPER II Tool..............................873 Table 5. Crimp Measurement.................................................874 Table 6. Current Rating....................................................876 Table 7. Crimp Conditions..................................................884 Table 8. Wire Strip Lengths................................................896 Table 9. Wire Strip Lengths................................................897 Table 10. Crimp Height - Dimension ........................................901 Table 11. Wire Size and Crimp Height.......................................912 Table 12. Wire Strip Length................................................913 Table 13. Wire Strip Length and Crimp Measurements.........................918 Table 14. Crimp Pull-Out Test..............................................921 Table 15. Wire Strip Length Specifications.................................922 Table 16. Wire Splice Size.................................................927
HYSTER C264 (N30ZDRS, N35-40ZRS N35ZDR, N45ZR N30ZDR, N35-40ZR) SERVICE MANUAL – PDF DOWNLOAD:
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