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Hyster C264 Service Manual – PDF DOWNLOAD
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Hyster C264 Service Manual – PDF DOWNLOAD
FILE DETAILS:
Hyster C264 Service Manual – PDF DOWNLOAD
Language : English
Pages : 918
Downloadable : Yes
File Type : PDF
Size: 45.9 MB
TABLE OF CONTENTS:
Hyster C264 Service Manual – PDF DOWNLOAD
0620SRM1186......................................................................... 1 toc............................................................................. 1 AC Motor Repair............................................................. 1 Safety Precautions Maintenance and Repair................................... 2 General..................................................................... 5 Traction Motor Repair....................................................... 5 Disassemble............................................................. 5 Inspect................................................................. 7 Assemble................................................................ 7 Drive End Bearing, Replace.............................................. 8 Hydraulic Motor Repair...................................................... 8 Disassemble............................................................. 8 Inspect................................................................. 10 Assemble................................................................ 10 Troubleshooting............................................................. 10 897446-4000SRM0481-(11-2006)-US-EN.................................................. 15 toc............................................................................. 15 Lift Cylinders.............................................................. 15 Safety Precautions Maintenance and Repair................................... 16 General..................................................................... 19 Description................................................................. 19 Lowering Control Valve.................................................. 20 Main Cylinder Repair........................................................ 21 Disassemble............................................................. 21 Assemble................................................................ 22 Free-Lift Cylinder Repair................................................... 24 Disassemble............................................................. 24 Assemble................................................................ 24 Troubleshooting............................................................. 26 899648-2240SRM0001-(01-2006)-US-EN.................................................. 29 toc............................................................................. 29 Industrial Battery.......................................................... 29 Safety Precautions Maintenance and Repair................................... 30 General..................................................................... 33 Lead-Acid Batteries......................................................... 33 Specific Gravity............................................................ 34 Chemical Reaction in a Cell................................................. 34 Electrical Terms............................................................ 35 Battery Selection........................................................... 36 Battery Voltage............................................................. 37 Battery as a Counterweight.................................................. 37 Battery Ratings............................................................. 38 Kilowatt-Hours.......................................................... 38 Battery Maintenance......................................................... 38 Safety Procedures....................................................... 38 Maintenance Records..................................................... 39 New Battery............................................................. 39 Cleaning Battery........................................................ 39 Adding Water to Battery................................................. 41 Hydrometer.............................................................. 42 Battery Temperature..................................................... 42 Charging Battery........................................................ 43 Types of Battery Charges............................................ 44 Methods of Charging................................................. 45 Troubleshooting Charger............................................. 46 Knowing When Battery Is Fully Charged............................... 46 Where to Charge Batteries............................................... 46 Equipment Needed.................................................... 46 Battery Connectors...................................................... 47 Battery Care............................................................ 47 tables.......................................................................... 29 Table 1. Battery Capacity Terms............................................. 38 910442-8000SRM0231-(12-2004)-US-EN.................................................. 51 toc............................................................................. 51 Metric and Inch (SAE) Fasteners............................................. 51 Safety Precautions Maintenance and Repair................................... 52 General..................................................................... 55 Threaded Fasteners...................................................... 55 Nomenclature, Threads................................................... 55 Strength Identification................................................. 56 Cotter (Split) Pins..................................................... 56 Fastener Torque Tables.................................................. 61 Conversion Table........................................................ 63 tables.......................................................................... 51 Table 1. Bolts and Screws................................................... 57 Table 2. Studs and Nuts..................................................... 58 Table 3. Torque Nuts........................................................ 59 Table 4. Torque Nuts With Nylon Insert...................................... 60 Table 5. Torque Values for Metric Fasteners*................................ 61 Table 6. Torque Values for Inch Fasteners*.................................. 62 Table 7. Conversion Table for Metric and English Units...................... 63 Table 8. Cotter Pin Dimensional Data........................................ 64 Table 9. Cotter Pin Dimensional Data........................................ 65 Table 10. Cotter Pin Dimensional Data....................................... 66 Table 11. Cotter Pin Dimensional Data....................................... 68 1523820-0630SRM1022-(11-2006)-US-EN................................................. 73 toc............................................................................. 73 Master Drive Unit........................................................... 73 Safety Precautions Maintenance and Repair................................... 74 HFK400 Master Drive Unit.................................................... 77 General................................................................. 77 Description............................................................. 77 Drive Unit Maintenance and Repair....................................... 78 Remove.............................................................. 78 Install............................................................. 79 Disassemble......................................................... 80 Assemble............................................................ 83 Troubleshooting......................................................... 91 GK Master Drive Unit........................................................ 93 General................................................................. 93 Description............................................................. 93 Maintenance and Repair.................................................. 94 Install................................................................. 95 Assemble................................................................ 95 Mounting Electric Motor............................................. 96 Pivoted Connection - Geared Steering................................ 96 Disassemble............................................................. 96 Troubleshooting......................................................... 97 tables.......................................................................... 73 Table 1. Tooth Contact Pattern.............................................. 88 1534737-2200SRM1058-(11-2006)-US-EN.................................................101 toc.............................................................................101 Troubleshooting and Adjustments Using the AC Controls Program (E............101 Safety Precautions Maintenance and Repair...................................102 General.....................................................................105 Computer Requirements...................................................105 Software, Install.......................................................105 Language Selection......................................................105 Demo Mode...............................................................106 Connect PC to Lift Truck................................................110 Starting AC Controls Program............................................111 Lift Truck Control Setup....................................................116 Change Lift Truck Serial Number or Hourmeter............................116 Setting Factory Default Values or Changing Lift Truck Parameters........118 Create New Custom Lift Truck Configuration..............................123 Lift Truck Configuration Properties.....................................126 Import New Lift Truck Configuration From Disk...........................130 Delete Custom Lift Truck Configuration or Password File.................132 Dash Display................................................................135 Custom Display Languages................................................135 Download Display Language...............................................138 Clear Operator Log......................................................140 Password Functions..........................................................142 Enable/Disable Password and Lift Truck Inspection Functions.............142 Truck Inspection Checklist..........................................142 Password............................................................142 Password Properties.....................................................144 Create New Password File................................................147 Download Passwords......................................................149 Upload Passwords........................................................151 Reports Menu................................................................153 Devices Report..........................................................153 Custom Report...........................................................155 Password Report.........................................................156 Operator Report.........................................................161 Current Settings Report.................................................164 Status Code Report......................................................166 Status Codes Log........................................................170 Troubleshooting.............................................................172 Diagnostics.............................................................172 Help Menu...................................................................175 General.................................................................175 Contents................................................................175 Technical Support.......................................................178 About Electric Truck AC Controls Program................................180 1580517-2200SRM1128-(03-2007)-US-EN.................................................185 toc.............................................................................185 Wire Harness Repair.........................................................185 Safety Precautions Maintenance and Repair...................................186 General.....................................................................189 Deutsch Crimping Tool.......................................................189 How to Strip a Wire for Use With Deutsch Crimping Tool..................189 How to Crimp With the Deutsch Crimping Tool.............................190 Calibration Test for the Deutsch Crimping Tool..........................191 Deutsch Connectors..........................................................193 DT, DTM, and DTP Series Connectors......................................193 Connector Receptacle Replacement....................................201 Connector Plug Replacement..........................................209 Connector Receptacle Pin Replacement................................217 Connector Plug Socket Replacement...................................226 HD Series Connectors....................................................235 Connector Receptacle Replacement....................................237 Connector Plug Replacement..........................................241 Connector Receptacle Pin Replacement................................244 Connector Plug Socket Replacement...................................250 Sealing Plugs...........................................................254 Metri-Pack Connectors.......................................................256 Remove and Install......................................................256 Micro-Pack Connectors.......................................................258 Weather-Pack Connectors.....................................................259 Weather-Pack Terminal Repair............................................259 Wire Repair.................................................................260 Wire Splicing Requirements..............................................260 Deutsch Jiffy Splice....................................................260 Assemble............................................................261 Disassemble.........................................................263 Del-City Crimp-Solder-Shrink Splice.....................................264 Twisted/Shielded Cable and Leads Repair.....................................266 Twisted/Shielded Cable Repair...........................................266 Twisted Leads Repair....................................................267 Special Tools...............................................................268 tables..........................................................................185 Table 1. Wire Strip Length Specifications...................................190 Table 2. Wire Splice Size...................................................264 1590933-0100SRM1185-(11-2006)-US-EN.................................................273 toc.............................................................................273 Frame.......................................................................273 Safety Precautions Maintenance and Repair...................................274 General.....................................................................277 Description.................................................................277 Repairs - General...........................................................278 Welding.................................................................278 Covers, Panels, and Plates..................................................278 Front Frame Panel (Left and Right)......................................278 Operator Compartment Cover..............................................279 Drive Unit Compartment Door.............................................279 Door Pad................................................................280 Operator Back Pad.......................................................280 Operator Front Pad......................................................280 Caster Wheel Cover......................................................280 Load Wheels.................................................................280 Remove..................................................................280 Install.................................................................281 Overhead Guard Replacement..................................................282 Remove..................................................................285 Install.................................................................285 Front Lights............................................................285 Bulb Replacement....................................................285 Assembly Replacement................................................286 Rear Work and Caution Light.........................................287 Caution Light.......................................................287 Painting Instructions.......................................................288 Safety Labels Replacement...................................................289 1590934-0620SRM1186-(11-2006)-US-EN.................................................295 toc.............................................................................295 AC Motor Repair.............................................................295 Safety Precautions Maintenance and Repair...................................296 General.....................................................................299 Traction Motor Repair.......................................................300 Disassemble.............................................................300 Inspect.................................................................300 Assemble................................................................301 Drive End Bearing, Replace..............................................302 Hydraulic Motor Repair......................................................303 Disassemble.............................................................303 Inspect.................................................................304 Assemble................................................................305 Troubleshooting.............................................................306 tables..........................................................................295 Table 1. Traction Motor Windings............................................301 Table 2. Hydraulic Motor Windings...........................................305 1590937-1600SRM1187-(11-2006)-US-EN.................................................309 toc.............................................................................309 Steering System.............................................................309 Safety Precautions Maintenance and Repair...................................310 General.....................................................................313 Discharging the Capacitors..............................................313 Raising the Lift Truck..................................................314 How to Raise the Drive Tire End.....................................314 How to Raise the Entire Lift Truck..................................315 Description.................................................................316 Steering Handle Assembly....................................................319 Fixed Handle............................................................319 Description.........................................................319 Remove..............................................................319 Disassemble.........................................................321 Assemble............................................................321 Install.............................................................323 Adjustable Handle.......................................................323 Description.........................................................323 Remove..............................................................323 Disassemble.........................................................324 Assemble............................................................327 Install.............................................................327 Steering Controller.........................................................328 Description.............................................................328 Remove..................................................................328 Disassemble.............................................................329 Assemble................................................................329 Install.................................................................329 Steering Proximity Switch...................................................329 Replace.................................................................329 Steering Motor..............................................................330 Description.............................................................330 Remove..................................................................330 Disassemble.............................................................331 Assemble................................................................331 Install.................................................................331 Caster Wheel Assembly (Nonsteered)..........................................332 Description.............................................................332 Remove..................................................................332 Disassemble.............................................................333 Upper and Lower Support Housings....................................333 Spring Assembly From Lower Support Assembly.........................334 Spring Assembly.....................................................334 Caster Spindle From Lower Support...................................334 Caster Wheels.......................................................334 Lower Support Housing...............................................336 Upper Support Housing...............................................336 Assemble................................................................337 Upper Support Housing...............................................337 Lower Support Housing...............................................338 Caster Wheels.......................................................339 Caster Spindle to Lower Support.....................................339 Spring Assembly.....................................................339 Spring Assembly to Lower Support....................................340 Upper and Lower Support Housings....................................340 Install.................................................................340 Adjust..................................................................341 Caster Assembly (Steered)...................................................342 Description.............................................................342 Remove..................................................................342 Disassemble.............................................................344 Upper and Lower Support.............................................344 Spring Assembly From Lower Support Housing..........................345 Spring Assembly.....................................................345 Caster Spindle From Lower Support...................................346 Caster Wheels.......................................................346 Lower Support Housing...............................................347 Upper Support Housing...............................................348 Caster Steering Motor...............................................349 Assemble................................................................349 Caster Steering Motor...............................................349 Upper Support Housing...............................................349 Lower Support Housing...............................................350 Caster Wheels.......................................................351 Caster Spindle to Lower Support.....................................351 Spring Assembly.....................................................352 Spring Assembly to Lower Support....................................352 Upper and Lower Support Housings....................................352 Install.................................................................353 Adjust..................................................................353 Caster Wheel Replacement................................................355 Remove..............................................................355 Install.............................................................356 Troubleshooting.............................................................356 tables..........................................................................309 Table 1. Upper Adjustment Gap Measurement...................................342 Table 2. Upper Adjustment Gap Measurement...................................355 1590938-1800SRM1188-(11-2006)-US-EN.................................................359 toc.............................................................................359 Brake System................................................................359 Safety Precautions Maintenance and Repair...................................360 Introduction................................................................363 General.................................................................363 Discharging the Capacitors..............................................363 Electric Brake..............................................................364 Air Gap.................................................................365 Remove..................................................................366 Install.................................................................366 Troubleshooting.............................................................367 1590939-1900SRM1189-(10-2006)-US-EN.................................................371 toc.............................................................................371 Hydraulic System............................................................371 Safety Precautions Maintenance and Repair...................................372 General.....................................................................375 Discharging the Capacitors..............................................376 Description.................................................................377 Control Handle..............................................................377 Side-Stance Control Handle..............................................377 Forward-Stance..........................................................378 Maintenance.................................................................379 Oil Level and Leaks.....................................................379 Operation...............................................................379 Oil Change..............................................................379 Drain...............................................................379 Cylinder Identification.............................................381 Fill................................................................382 Main Lift Cylinders.............................................382 Free-Lift Cylinders.............................................383 Breather Cap............................................................384 Inspect.............................................................384 Oil Filter..............................................................384 Change..............................................................384 Oil Strainer............................................................385 Check...............................................................385 Hydraulic System............................................................385 General.................................................................385 Cleaning............................................................385 Noise Levels........................................................385 Hoses...................................................................386 Fittings................................................................388 Lift Pump and Motor.........................................................388 Complete Unit...........................................................388 Remove..............................................................388 Install.............................................................389 Lift Pump...............................................................391 Components..........................................................391 Pressure Flange Fitting.........................................391 Supply and Return Fittings......................................392 Manual Lowering Valve...........................................392 Pressure Test Ports.............................................393 Pressure Transducer.............................................393 Relief Valve....................................................395 Lowering Control Valve..........................................395 Remove Pump.........................................................396 Install Pump........................................................396 Auxiliary Hydraulics........................................................397 Auxiliary Pump and Motor................................................397 Remove..............................................................397 Disassemble.........................................................398 Assemble............................................................398 Install.............................................................399 Front Selector Valve....................................................399 Rear Selector Valve.....................................................400 Hydraulic Tank..............................................................402 Remove..................................................................402 Disassemble.............................................................403 Breather Assembly...................................................403 Filter Assembly.....................................................405 Low Oil Indicator Switch............................................406 Tank Fittings.......................................................406 Clean and Inspect.......................................................406 Assemble................................................................407 Breather Assembly...................................................407 Filter Assembly.....................................................407 Low Oil Indicator Switch............................................407 Tank Fittings.......................................................407 Install.................................................................407 Specifications..............................................................408 Troubleshooting.............................................................409 tables..........................................................................371 Table 1. Main Lift Pump and Motor Configurations............................377 Table 2. Cylinder Identification............................................382 1590940-2200SRM1190-(02-2007)-US-EN.................................................413 toc.............................................................................413 AC Motor Controllers/ Display Panel.........................................413 Safety Precautions Maintenance and Repair...................................414 Description.................................................................417 General.................................................................417 AC Motors...........................................................417 Motor Controllers...................................................417 Master Controller...................................................418 Dash Display........................................................418 Controller Area Network Bus (CANbus)................................418 AC Transistor Motor Controller Replacement..................................419 General.................................................................419 General Maintenance Instructions........................................420 Special Precautions.................................................421 Fuses...................................................................421 Fan.....................................................................422 Contactors..............................................................422 Repair..............................................................422 Master Controller Checks and Adjustments....................................423 Function Settings...........................................................423 General.................................................................423 Troubleshooting.............................................................425 General.................................................................425 Controller Status Light Emitting Diodes (LEDs)..........................426 Master Controller...................................................426 AC Motor Controllers................................................426 Operator Status Messages................................................429 Status Codes............................................................433 Display Panel...............................................................497 General.................................................................497 Premium Display Panel...............................................497 Standard Display Panel..............................................498 Standard Display Functions and Features.....................................499 Key-On Initialization...................................................499 Passwords...............................................................499 Performance Modes.......................................................500 Battery Discharge Indicator (BDI).......................................500 Hourmeters..............................................................500 Standard Dash Display Service Menu Navigation...............................501 General.................................................................501 Moving Through Menu Selections..........................................501 Editing and Adding Information..........................................501 Access to Service Functions.............................................502 Service Functions.......................................................502 Premium Display Functions and Features......................................504 Key-On Initialization...................................................504 Passwords...............................................................504 Operator Checklist Function.............................................504 Performance Modes.......................................................504 Battery Discharge Indicator.............................................505 Hourmeters..............................................................505 Shelf Height Selector...................................................505 Premium Dash Display Service Menu Navigation................................506 General.................................................................506 Moving Through Menu Selections..........................................506 Access to Service Functions.............................................507 Service Functions.......................................................507 Connector Pin-Outs..........................................................509 System Logic Diagram........................................................516 tables..........................................................................413 Table 1. Factory Parameter Defaults.........................................423 Table 2. Traction Parameter Defaults........................................425 Table 3. List of Operator Warning Messages..................................429 Table 4. List of Fault Messages.............................................433 Table 5. Password Prompt Screen.............................................499 Table 6. Password Reminder Screen...........................................499 Table 7. Password Prompt Screen.............................................501 Table 8. Password Prompt Screen.............................................502 Table 9. Password Prompt Screen.............................................504 Table 10. Password Screen...................................................504 Table 11. Password Prompt Screen............................................506 Table 12. Password Prompt Screen............................................507 1590941-2200SRM1191-(03-2007)-US-EN.................................................521 toc.............................................................................521 Electrical System...........................................................521 Safety Precautions Maintenance and Repair...................................522 General.....................................................................527 Discharging the Capacitors..............................................528 Static Strap............................................................528 Inspect.............................................................528 Replace.............................................................528 Battery Connection..........................................................529 Inspect.................................................................529 Replacing Cables........................................................529 Key Switch..................................................................530 Replace.................................................................530 Contactors..................................................................532 Function................................................................532 Testing.................................................................533 Remove..................................................................534 Install.................................................................534 EE Contactors...........................................................534 Motor Controllers...........................................................536 Functions...............................................................536 Master Controller...................................................536 Steering Motor Controller...........................................536 Traction Motor Controller...........................................536 Lift Motor Controller...............................................536 Steer Caster Controller (Optional)..................................536 Replace.................................................................536 Traction and Lift Motor Controllers.................................537 Steering and Master Controllers.....................................537 Steer Caster Controller (Option)....................................537 Integrated Fuse Board (IFB).................................................538 Fuses...................................................................538 Replace.................................................................539 Power Disconnect Switch.....................................................539 Replace.................................................................539 Multifunction Control Handle................................................541 Sidestance Control Handle...............................................541 Remove..................................................................541 Disassemble.............................................................542 Assemble................................................................542 Install.................................................................542 Fore/Aft Stance Controls....................................................544 Repair..................................................................544 Steering Handle.............................................................546 Steering Unit Repair....................................................546 Foot Switches...............................................................550 Brake Switch............................................................550 Operator Sensing........................................................550 Repair..................................................................550 Dash Display Assembly.......................................................552 Description.............................................................552 Remove..................................................................552 Test....................................................................553 Install.................................................................553 Horn........................................................................554 Audible Alarm...........................................................554 Light Assemblies............................................................555 Front Lights............................................................555 Bulb Replacement....................................................555 Assembly Replacement................................................555 Rear Work and Caution Light.............................................556 Rear Work Light.....................................................556 Caution Light.......................................................556 Light Switches..........................................................557 Cooling Fans................................................................559 Electrical Compartment Fans.............................................559 Replace.............................................................560 Operator Fan............................................................560 Repair..............................................................560 Impact Sensor...............................................................563 Remove..................................................................563 Install.................................................................563 Height Proximity Switch.....................................................564 Test....................................................................564 Remove..................................................................564 Install.................................................................565 Adjust..................................................................565 Load Transport Proximity Switch.............................................566 Replace.................................................................566 Adjust..................................................................567 Fork Height Sensor Option...................................................567 Remove..................................................................567 Encoder Assembly....................................................567 Timing Belt.........................................................568 Install.................................................................568 Encoder Assembly....................................................568 Timing Belt.........................................................569 Reach Position Sensor.......................................................570 Remove..................................................................570 Install.................................................................572 Retract Sensor..............................................................573 Remove..................................................................573 Install.................................................................573 Tilt Leveling...............................................................575 Remove..................................................................575 Install.................................................................575 Laser Option................................................................576 Remove..................................................................576 Install.................................................................576 Camera Option...............................................................576 Remove..................................................................576 Install.................................................................577 Wiring Harness..............................................................577 1590942-2200SRM1192-(11-2006)-US-EN.................................................585 toc.............................................................................585 User Interface..............................................................585 Safety Precautions Maintenance and Repair...................................586 General.....................................................................589 Description.............................................................589 Dash Display Menu Access................................................589 Menu Navigation.............................................................590 Standard Display........................................................590 Main Menu...................................................................590 Passwords Menu..............................................................590 Add Password............................................................591 Delete Password.........................................................592 Edit Password...........................................................593 1590943-2200SRM1193-(11-2006)-US-EN.................................................597 toc.............................................................................597 User Interface..............................................................597 Safety Precautions Maintenance and Repair...................................598 General.....................................................................601 Description.............................................................601 Dash Display Menu Access................................................601 Menu Navigation.............................................................602 Standard Display........................................................602 Main Menu...................................................................602 Diagnostics Menu............................................................602 Static Diagnostics......................................................602 Traction System.........................................................606 Hydraulic System........................................................607 Steer System............................................................609 General Truck...........................................................610 Error Log...............................................................611 View Hourmeters.............................................................611 Truck Hours.............................................................611 Traction Hours..........................................................612 Pump Hours..............................................................612 Auxiliary Hours.........................................................613 Setup Menu..................................................................613 Lift Settings...........................................................613 Lift Maximum Speed..................................................613 Lower Maximum Speed.................................................614 Lift Acceleration...................................................614 Lower Acceleration..................................................615 Lift Deceleration...................................................615 Lower Deceleration..................................................616 Auxiliary Settings......................................................616 Fast Extend Speed...................................................616 Slow Extend Speed...................................................617 Fast Retract Speed..................................................617 Slow Retract Speed..................................................618 Tilt Up Speed.......................................................618 Tilt Down Speed.....................................................619 Sideshift Speed.....................................................619 Cushioning Speed....................................................620 Steer Settings..........................................................620 Steer Mode..........................................................620 Steer Effort........................................................622 Steer Ratio.........................................................622 Truck Settings..........................................................623 Truck Serial Number.................................................623 Truck Voltage.......................................................623 Truck Capacity......................................................624 Truck Type..........................................................624 BDI Adjust Calibration..............................................625 Autotilt Option.....................................................625 Carry Level Option..................................................626 Simultaneous Hydraulics.............................................626 Audible Alarm.......................................................627 Visible Alarm.......................................................627 Password Option.....................................................628 Traction Settings.......................................................628 Rabbit Speed........................................................628 Rabbit Acceleration.................................................630 High Speed..........................................................630 High Acceleration...................................................631 Mid Speed...........................................................631 Mid Acceleration....................................................632 Turtle Speed........................................................632 Turtle Acceleration.................................................633 Neutral Braking.....................................................633 Plug Braking........................................................634 View Software Versions......................................................634 Master Controller.......................................................634 Display.................................................................635 Traction Controller.....................................................635 Hydraulic Controller....................................................636 Control Handle..........................................................636 Remote CAN Module ( N35ZDR, N45ZR, N30ZDR, N35-40ZR Only)...............637 Caster Controller.......................................................637 Password Menu...............................................................638 Add Password............................................................638 Delete Password.........................................................638 Edit Password...........................................................640 tables..........................................................................597 Table 1. Password Screen....................................................601 Table 2. Static Diagnostics Menu............................................603 Table 3. Traction System Diagnostics Menu...................................606 Table 4. Hydraulic System Diagnostics Menu..................................607 Table 5. Steering System Diagnostics Menu...................................609 Table 6. General Truck Diagnostics Menu.....................................610 Table 7. Error Log..........................................................611 Table 8. Truck Hours........................................................611 Table 9. Traction Hours.....................................................612 Table 10. Pump Hours........................................................612 Table 11. Auxiliary Hours...................................................613 Table 12. Lift Maximum Speed Menu...........................................613 Table 13. Lower Maximum Speed Menu..........................................614 Table 14. Lift Acceleration Menu............................................614 Table 15. Lower Acceleration Menu...........................................615 Table 16. Lift Deceleration Menu............................................615 Table 17. Lower Deceleration Menu...........................................616 Table 18. Fast Extend Speed Menu............................................616 Table 19. Slow Extend Speed Menu............................................617 Table 20. Fast Retract Speed Menu...........................................617 Table 21. Slow Retract Speed Menu...........................................618 Table 22. Tilt Up Speed Menu................................................618 Table 23. Tilt Down Speed Menu..............................................619 Table 24. Sideshift Speed Menu..............................................619 Table 25. Cushioning Speed Menu.............................................620 Table 26. Steer Mode Menu...................................................621 Table 27. Steer Effort Menu.................................................622 Table 28. Steer Ratio Menu..................................................622 Table 29. Truck Serial Number Menu..........................................623 Table 30. Truck Voltage Menu................................................623 Table 31. Truck Capacity Menu...............................................624 Table 32. Truck Type Menu...................................................624 Table 33. BDI Adjust Calibration Menu.......................................625 Table 34. Autotilt Option Menu..............................................625 Table 35. Carry Level Option Menu...........................................626 Table 36. Simultaneous Hydraulics Menu......................................626 Table 37. Audible Alarm Menu................................................627 Table 38. Visible Light Alarm Menu..........................................627 Table 39. Password Option Menu..............................................628 Table 40. Rabbit Speed Menu.................................................628 Table 41. Rabbit Acceleration Menu..........................................630 Table 42. High Speed Menu...................................................630 Table 43. High Acceleration Menu............................................631 Table 44. Mid Speed Menu....................................................631 Table 45. Mid Acceleration Menu.............................................632 Table 46. Turtle Speed Menu.................................................632 Table 47. Turtle Acceleration Menu..........................................633 Table 48. Neutral Braking Menu..............................................633 Table 49. Plug Braking Menu.................................................634 Table 50. Master Controller Software Version................................634 Table 51. Display Software Version..........................................635 Table 52. Traction Controller Software Version..............................635 Table 53. Hydraulic Controller Software Version.............................636 Table 54. Control Handle Software Version...................................636 Table 55. Remote CAN Module Software Version................................637 Table 56. Caster Controller Software Version................................637 1590945-4000SRM1194-(11-2006)-US-EN.................................................643 toc.............................................................................643 Mast........................................................................643 Safety Precautions Maintenance and Repair...................................644 General.....................................................................647 Safety Procedures When Working Near Mast....................................649 Mast Weldments..............................................................650 Reach Carriage Assembly.....................................................650 Three-Stage Mast............................................................652 Description.............................................................652 Operation...............................................................653 1590956-4000SRM1195-(11-2006)-US-EN.................................................657 toc.............................................................................657 Mast........................................................................657 Safety Precautions Maintenance and Repair...................................658 General.....................................................................661 Safety Procedures When Working Near Mast....................................661 Load Backrest...............................................................662 Remove..................................................................662 Install.................................................................662 Forks.......................................................................663 Remove..................................................................663 Install.................................................................663 Checks..................................................................664 Sheaves.....................................................................664 Hydraulic System............................................................667 Hydraulic Oil...........................................................669 Drain...............................................................669 Cylinder Identification.............................................670 Fill................................................................672 Main Lift Cylinders.............................................672 Free-Lift Cylinders.............................................673 Reach Carriage Assembly.....................................................674 Remove..................................................................674 Install.................................................................675 Load Rollers................................................................676 Mast....................................................................676 Reach Assembly..........................................................678 Load Rollers........................................................678 Side Rollers........................................................678 Mast........................................................................679 Remove..................................................................679 Disassemble.............................................................680 Clean and Inspect.......................................................681 Assemble................................................................683 Install.................................................................684 Lift Cylinders..............................................................685 Main Lift Cylinders.....................................................685 Remove..............................................................685 Install.............................................................685 Free-Lift Cylinder......................................................688 Remove..............................................................688 Install.............................................................690 Lift Chains.................................................................691 Clean and Inspect.......................................................691 Mast Adjustments............................................................692 General.................................................................692 Mast Back Angle Adjustment..............................................692 Load Rollers Adjustment.................................................693 Reach Carriage Assembly.............................................693 Adjust Wear Plugs - Mast................................................694 Adjust Main-Lift Chains.................................................695 Adjust Free-Lift Chain..................................................695 Adjust Wear Strips......................................................697 Mast Racking............................................................698 Proximity Switches......................................................700 Replace.............................................................700 Free-Lift Proximity Switch......................................700 Load Lowering Proximity Switch (Optional).......................701 Adjust..............................................................701 Mast Operation Check........................................................701 Lift System Leak Check......................................................702 Lift Cylinder Leak Check................................................702 Tilt Cylinder Leak Check................................................702 tables..........................................................................657 Table 1. Fork Tip Alignment.................................................664 Table 2. Cylinder Identification............................................671 1590957-4500SRM1196-(02-2007)-US-EN.................................................705 toc.............................................................................705 Reach Carriages.............................................................705 Safety Precautions Maintenance and Repair...................................706 General.....................................................................709 Safety Procedures When Working Near Mast....................................709 Description.................................................................710 Repair - General............................................................712 Load Backrest...............................................................712 Remove..................................................................712 Install.................................................................712 Forks.......................................................................713 Replacement.............................................................713 Remove..............................................................713 Install.............................................................713 Reach Carriage Assembly.....................................................713 Remove..................................................................713 Inspect.................................................................715 Install.................................................................715 Reach Carriage Assembly Repair..............................................716 Load Rollers Repair.........................................................717 Side Rollers Repair (6.9 Mast Only) (N30ZDRS and N35-40ZRS).................718 Reach Assembly Front Frame..................................................718 Remove..................................................................718 Disassemble (With Sideshift)............................................719 Disassemble (Without Sideshift).........................................721 Clean and Inspect.......................................................722 Assemble (With Sideshift)...............................................722 Assemble (Without Sideshift)............................................722 Install.................................................................722 Single-Reach Scissor Arms...................................................723 Remove and Disassemble..................................................723 Clean and Inspect.......................................................726 Assemble and Install....................................................726 Double-Reach Scissor Arms...................................................728 Disassemble.............................................................729 Clean and Inspect.......................................................731 Assemble................................................................731 Rear Frame Assembly.........................................................733 Remove..................................................................733 Disassemble.............................................................735 Clean and Inspect.......................................................736 Assemble................................................................736 Install.................................................................736 Reach Cylinders.............................................................738 Remove..................................................................738 Disassemble.............................................................739 Clean and Inspect.......................................................740 Assemble................................................................740 Install.................................................................740 Tilt Cylinder...............................................................741 Remove..................................................................741 Clean, Inspect, and Repair..............................................741 Install.................................................................741 Sideshift Cylinder..........................................................743 Repair..................................................................743 Front Selector Valve........................................................744 Rear Selector Valve.........................................................745 Reach Assembly Adjustments..................................................746 Check Adjustment........................................................746 Adjust Side Rollers and Load Rollers....................................747 Adjust Reach Cylinders..................................................748 Lift Chains.................................................................749 Inspect.................................................................749 Clean and Lubricate.....................................................749 Adjust Main-Lift Chains.................................................750 Adjust Free-Lift Chains.................................................750 Specifications..............................................................752 Troubleshooting ............................................................755 tables..........................................................................705 Table 1. General Specifications.............................................752 Table 2. Operating Times ...................................................753 1590959-8000SRM1197-(02-2007)-US-EN.................................................759 toc.............................................................................759 Periodic Maintenance........................................................759 Safety Precautions Maintenance and Repair...................................760 General.....................................................................763 Removing Covers.........................................................763 Front Frame Panel (Left and Right)..................................763 Operator Compartment Cover..........................................764 Drive Unit Compartment Door.........................................765 Caster Wheel Cover..................................................765 Discharging the Capacitors..............................................765 How to Move Disabled Truck..............................................766 How to Tow Lift Truck...............................................766 How to Put Lift Truck on Blocks.........................................767 How to Raise Load Wheels............................................767 How to Raise the Drive Tire End.....................................768 How to Raise the Entire Lift Truck..................................768 Manual Lowering Valve...................................................769 N30-35ZDR and N35-40-45ZR ..........................................769 N30ZDRS and N35-40ZRS ..............................................770 Safety Procedures When Working Near Mast....................................770 Maintenance Schedule........................................................771 Maintenance Procedures Every 8 Hours or Daily...............................776 Checks With Key Switch Turned OFF.......................................776 Battery.............................................................776 Tires and Wheels....................................................777 Frame and Load Wheels...............................................777 Safety Labels.......................................................778 Overhead Guard......................................................778 Forks Check.........................................................778 Lift Chain Check....................................................779 Mast Check..........................................................780 Reach, Tilt, and Sideshift..........................................780 Checks With Key Switch Turned ON........................................780 Operation...........................................................780 Hydraulic System....................................................781 Dash Display........................................................783 Lift System Operation...............................................784 Multifunction Control Handle........................................785 Brake...............................................................785 Steering System.....................................................785 Maintenance Procedures Every 500 Hours or 3 Months..........................785 Master Drive Unit.......................................................785 Hydraulic System........................................................786 Caster Wheel Assembly Adjustment Procedure..............................786 Drive Tire Check........................................................788 Lift System Operation...................................................788 Forks...............................................................788 Mast................................................................788 Lift Chains.........................................................789 Other Lubrication.......................................................789 Maintenance Procedures Every 2000 Hours or Yearly...........................789 Brakes..................................................................789 Check...............................................................789 Electric System.........................................................790 Main Contactor......................................................790 Inspect.........................................................790 Hydraulic System........................................................790 Drain...............................................................790 Cylinder Identification.........................................792 Fill................................................................793 Main Lift Cylinders.............................................793 Free-Lift Cylinders.............................................794 Hydraulic Filter Change.............................................795 Check Hydraulic Strainer............................................795 Lift and Tilt System Leaks Check............................................796 Lift System.............................................................796 Tilt System.............................................................796 Battery Maintenance.........................................................797 How to Charge Battery...................................................797 How to Change Battery...................................................798 Tires and Wheels............................................................801 Drive Tire..............................................................801 How to Change Drive Tire................................................801 Tandem Load Wheels......................................................802 Caster Wheels...........................................................802 Remove..............................................................802 Install.............................................................803 Preparation for Storage.....................................................804 Short-Term Storage (1 to 6 months)......................................804 Long-Term Storage (6 months or longer)..................................804 Transporting................................................................804 Loading.................................................................804 Unloading...............................................................805 Preparation for Use.........................................................805 Preparation After Shipment..............................................805 Preparation After Storage...............................................805 tables..........................................................................759 Table 1. Maintenance Schedule...............................................772 Table 2. Fork Tip Alignment.................................................778 Table 3. Hydraulic Tank Capacities..........................................782 Table 4. Upper Adjustment Gap Measurement...................................787 Table 5. Free-Lift Cylinder Rod Widths......................................793 Table 6. Battery Size Specifications........................................800 Table 7. Tires and Wheels...................................................801 1590961-8000SRM1198-(02-2007)-US-EN.................................................809 toc.............................................................................809 Capacities and Specifications...............................................809 Safety Precautions Maintenance and Repair...................................810 Lubrication Specifications..................................................813 Oil Capacities..............................................................813 Hydraulic System............................................................814 Lift Specifications.........................................................815 Tire Sizes..................................................................819 Torque Specifications.......................................................820 Master Drive Unit.......................................................820 Reach Carriage..........................................................820 Mast....................................................................820 Hydraulic System ( N30-35ZDR and N35-40-45ZR )..........................820 Hydraulic System ( N30ZDRS and N35-40ZRS )..............................820 Steering System.........................................................821 Load Wheels.............................................................821 Fuses.......................................................................821 Coil Resistance Values......................................................821 Battery Specifications......................................................822 1590963-8000SRM1199-(02-2007)-US-EN.................................................827 toc.............................................................................827 Diagrams....................................................................827 Safety Precautions Maintenance and Repair...................................828 1622432-2200SRM1240-(11-2006)-US-EN.................................................865 toc.............................................................................865 User Interface..............................................................865 Safety Precautions Maintenance and Repair...................................866 General.....................................................................869 Description.............................................................869 Dash Display Menu Access................................................869 Menu Navigation.............................................................870 Main Menu...................................................................870 Passwords Menu..............................................................870 View Operator Log.......................................................871 Add Password............................................................872 Delete Password.........................................................873 Edit Password...........................................................874 tables..........................................................................865 Table 1. Enter Password Screen..............................................869 1622433-2200SRM1241-(11-2006)-US-EN.................................................877 toc.............................................................................877 User Interface..............................................................877 Safety Precautions Maintenance and Repair...................................878 General.....................................................................881 Description.............................................................881 Dash Display Menu Access................................................881 Menu Navigation.............................................................882 Main Menu...................................................................882 Diagnostics Menu............................................................882 Static Diagnostics......................................................882 Traction System.........................................................884 Hydraulic System........................................................884 Steer System............................................................885 General Truck...........................................................886 Height Sensor.......................................................886 Calibrate Fork Tare Down............................................886 Calibrate Fork Tare Up..............................................886 Calibrate Cushion Inpoint ( N35ZDR, N45ZR, N30ZDR, N35-40ZR Only....886 Calibrate Cushion Outpoint ( N35ZDR, N45ZR, N30ZDR, N35-40ZR Onl....886 Calibrate Mast Slowdown.............................................886 Error Log...............................................................887 View Hourmeters.............................................................888 Truck...................................................................888 Traction................................................................888 Pump....................................................................888 Auxiliary...............................................................888 Setup Menu..................................................................889 Lift Settings...........................................................889 Lift Maximum Speed..................................................889 Lower Maximum Speed.................................................889 Lift Acceleration...................................................890 Lower Acceleration..................................................890 Lift Deceleration...................................................890 Lower Deceleration..................................................891 Auxiliary Settings......................................................891 Fast Extend Speed...................................................891 Slow Extend Speed...................................................891 Fast Retract Speed..................................................892 Slow Retract Speed..................................................892 Tilt Up Speed.......................................................892 Tilt Down Speed.....................................................892 Sideshift Speed.....................................................892 Cushioning Speed....................................................892 Steer Settings..........................................................893 Steer Mode..........................................................893 Steer Effort........................................................893 Steer Ratio.........................................................893 Display Settings........................................................894 Display Language....................................................894 Year, Month, Date, Hour, Minute, and Second.........................894 Truck Settings..........................................................895 Serial Number.......................................................895 Voltage.............................................................895 Capacity Lbs........................................................895 Carriage Type.......................................................895 BDI Adjust Calibration..............................................895 Load Weight Option..................................................896 Shelf Height Enable.................................................896 Auto Tilt Option....................................................896 Carry Level Option..................................................896 Simultaneous Hydraulics.............................................896 Audible Alarm.......................................................896 Visible Alarm Option................................................896 Password Option.....................................................896 Shutdown Timeout....................................................896 Traction Settings.......................................................897 Rabbit Speed........................................................897 Rabbit Acceleration.................................................897 High Speed..........................................................897 High Acceleration...................................................897 Mid Speed...........................................................898 Mid Acceleration....................................................898 Turtle Speed........................................................898 Turtle Acceleration.................................................898 Neutral Braking.....................................................898 Plug Braking........................................................898 View Software Versions......................................................899 Master Controller.......................................................899 Display.................................................................899 Traction Controller.....................................................899 Hydraulic Controller....................................................899 Control Handle..........................................................899 Remote CAN Module ( N35ZDR, N45ZR, N30ZDR, N35-40ZR Only)...............899 Steer Controller........................................................899 Caster Controller.......................................................899 Passwords Menu..............................................................900 Functions...............................................................901 View Operator Log...................................................901 Add Password........................................................902 Delete Password.....................................................903 Edit Password.......................................................904 Setup Shelf Height..................................................905 Learn Shelf Height..................................................905 tables..........................................................................877 Table 1. Enter Password Screen..............................................881 Table 2. Static Diagnostics Menu............................................883 Table 3. Traction System Menu...............................................884 Table 4. Hydraulic System Menu..............................................884 Table 5. Steer System Menu..................................................885 Table 6. General Truck Menu.................................................886 1655577R0...........................................................................909 1655577R1...........................................................................914
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