Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Sale!
Hyster C470 Service Manual – PDF DOWNLOAD
Original price was: $87.95.$31.95Current price is: $31.95.
Hyster C470 Service Manual – PDF DOWNLOAD
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
Hyster C470 Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster C470 Service Manual – PDF DOWNLOAD
SAFETY PRECAUTIONS MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair
on electric lift trucks. Disconnect the battery ground cable on internal combustion lift
trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance
section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit whenmaking repairs,
or if the unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.
TABLE OF CONTENTS:
Hyster C470 Service Manual – PDF DOWNLOAD
897076-0620SRM0294-(03-2006)-US-EN.................................................. 1 toc............................................................................. 1 DC Motor Maintenance........................................................ 1 Safety Precautions Maintenance and Repair................................... 2 General..................................................................... 5 Brush and Commutator Inspection............................................. 5 Hydraulic Pump Motor and Traction Motor................................. 5 Steering Pump Motor..................................................... 7 Normal Commutator Surface............................................... 7 Commutator Problems..................................................... 7 Brush Replacement........................................................... 12 Stoning the Commutator...................................................... 14 Motors Repair............................................................... 16 Disassemble............................................................. 16 Traction Motor and Hydraulic Pump Motor............................. 16 Steering Pump Motor................................................. 18 Assemble................................................................ 20 Traction Motor and Hydraulic Pump Motor............................. 20 Steering Pump Motor................................................. 21 Brush Alignment, Traction and Hydraulic Motors.............................. 23 Tests for Damaged Field and Armature........................................ 23 Test for an Open Circuit in Armature.................................... 23 Test for Short Circuit in One Armature Winding.......................... 24 Test for Short Circuit to Armature Shaft................................ 24 Test for Open Circuit in Field Coil..................................... 24 Test for Short Circuit in Field Coil.................................... 25 Test for Short Circuit Between Field and Motor Case..................... 25 Brush Holder Test....................................................... 25 Troubleshooting............................................................. 25 tables.......................................................................... 1 Table 1. Normal Commutator Surfaces......................................... 8 Table 2. Commutator Problems................................................ 9 Table 3. Brush Wear Replacement Guide....................................... 12 897445-4000SRM0480-(11-2006)-US-EN.................................................. 31 toc............................................................................. 31 Mast........................................................................ 31 Safety Precautions Maintenance and Repair................................... 32 General..................................................................... 35 Mast Weldments.............................................................. 35 Carriages................................................................... 37 Two-Stage Mast.............................................................. 40 Description............................................................. 40 Operation............................................................... 44 Three-Stage Mast............................................................ 45 Description............................................................. 45 Operation............................................................... 48 897446-4000SRM0481-(11-2006)-US-EN.................................................. 53 toc............................................................................. 53 Lift Cylinders.............................................................. 53 Safety Precautions Maintenance and Repair................................... 54 General..................................................................... 57 Description................................................................. 57 Lowering Control Valve.................................................. 58 Main Cylinder Repair........................................................ 59 Disassemble............................................................. 59 Assemble................................................................ 60 Free-Lift Cylinder Repair................................................... 62 Disassemble............................................................. 62 Assemble................................................................ 62 Troubleshooting............................................................. 64 897495-2200SRM0514-(01-2004)-US-EN.................................................. 67 toc............................................................................. 67 Instrument Cluster.......................................................... 67 Safety Precautions Maintenance and Repair................................... 68 General..................................................................... 71 Description................................................................. 71 Display Panels on Steering Column, Internal Combustion.................. 71 Display Panels on Steering Column, Electric Lift Trucks................. 76 Standard Display Panel.............................................. 76 Enhanced Display Panel.............................................. 77 Curtis 1215 Display Panel............................................... 81 Description and Features............................................ 81 Operation........................................................... 81 Cluster-Type Display Panel (Internal Combustion) Replacement................ 82 Remove and Disassemble.................................................. 82 Assemble and Install.................................................... 85 Cluster Display Panel (Electric Lift Truck) Replacement..................... 87 Display Panel Assembly, Replace......................................... 87 LED Indicators.......................................................... 87 Battery Indicators...................................................... 88 Digital Display (Enhanced Display Panel Only)........................... 88 Status Code or Performance Level Switches and LED indicators (En........ 88 Standard Display Panel Parts, Replace................................... 88 Enhanced Display Panel Parts, Replace................................... 89 Curtis 1215 Display Panel Replacement....................................... 89 Remove.................................................................. 89 Install................................................................. 89 tables.......................................................................... 67 Table 1. Instrument Cluster, Internal Combustion............................ 71 899648-2240SRM0001-(06-2007)-US-EN.................................................. 93 toc............................................................................. 93 Industrial Battery.......................................................... 93 Safety Precautions Maintenance and Repair................................... 94 General..................................................................... 97 Lead-Acid Batteries......................................................... 97 Specific Gravity............................................................ 98 Chemical Reaction in a Cell................................................. 98 Electrical Terms............................................................ 99 Battery Selection...........................................................100 Battery Voltage.............................................................101 Battery as a Counterweight..................................................101 Battery Ratings.............................................................102 Kilowatt-Hours..........................................................102 Battery Maintenance.........................................................102 Safety Procedures.......................................................102 Maintenance Records.....................................................103 New Battery.............................................................103 Cleaning Battery........................................................103 Adding Water to Battery.................................................105 Hydrometer..............................................................106 Battery Temperature.....................................................106 Charging Battery........................................................107 Types of Battery Charges............................................108 Methods of Charging.................................................109 Troubleshooting Charger.............................................110 Knowing When Battery Is Fully Charged...............................110 Where to Charge Batteries...............................................110 Equipment Needed....................................................110 Battery Connectors......................................................111 Battery Care............................................................111 tables.......................................................................... 93 Table 1. Battery Capacity Terms.............................................102 910114-2260SRM0138-(10-2005)-US-EN..................................................115 toc.............................................................................115 Battery Indicators..........................................................115 Safety Precautions Maintenance and Repair...................................116 General.....................................................................119 Indicators With Meter Movements.........................................119 Battery Indicators With LCD or LED Displays.............................122 Liquid Crystal Displays.............................................122 Display Panels Description (ZX or Earlier Motor Controllers)....122 SEM Display Panels Description......................................124 Light Emitting Diode Displays.......................................125 Description LX Series...............................................125 ZX Series Display Panels Description................................127 SEVCON POWERGAUGE™ Battery Display Panel Description................128 Battery Indicators Without Lift Interrupt Adjustment (Early Mode............128 Battery Indicators With Lift Interrupt Adjustment (Early Models)............129 Reset Potentiometer.....................................................129 Specific Gravity Alarm..................................................129 Battery Indicators Without Lift Interrupt Check (Later Models)..............130 Battery Indicators With Lift Interrupt Adjustment (Later Models)............130 Reset Potentiometer.....................................................130 Discharge Potentiometer.................................................130 LED Display With Lift Interrupt.............................................131 Curtis 933-1 Meter Check and Adjustment.....................................131 Check...................................................................131 Reset Check.........................................................132 Discharge Check.....................................................133 Lockout Check.......................................................133 LEDs Do Not Illuminate..............................................133 Hourmeter Check.....................................................133 Hourglass Icon......................................................133 Adjust..................................................................134 SEVCON POWERGAUGE™ Adjustment...............................................134 Curtis Dash Display Assembly................................................134 Description/Features....................................................134 Operation...............................................................135 Testing.................................................................136 Inoperative Dash Display Assembly...................................136 Inoperative Drive Mode Selection....................................136 Troubleshooting With a Programmer Handset...........................136 Troubleshooting Without a Programmer Handset........................137 No Warnings or Faults Displayed.....................................137 MIB/Dash Display Communication......................................138 Lift Interrupt......................................................138 Lost MIB Signal Displayed...........................................139 Lift Pump Hourmeter Input...........................................139 Forward/Reverse Hourmeter Inputs....................................139 Remove..................................................................140 Install.................................................................140 Adjust (Setup, Early Models)............................................140 Adjust (Setup, Later Model).............................................141 Battery Indicators Replacement..............................................142 Battery Indicator Controller Replacement....................................142 Display Panel Components Replacement........................................143 SEM Display Panel Replacement...............................................143 Remove and Replace......................................................143 tables..........................................................................115 Table 1. Battery Indicator (Later Models)...................................130 Table 2. SEVCON Discharge Curve Selector Positions..........................134 Table 3. Dash Display Drive Mode Inputs.....................................137 Table 4. Dash Display Drive Mode Test Voltages..............................137 Table 5. Dash Display Status/Warning/Fault Test Voltages....................138 Table 6. Testing Dash Display Status/Warning/Fault Inputs...................138 Table 7. Battery Indicator Reset Adjustment.................................141 910442-8000SRM0231-(12-2004)-US-EN..................................................149 toc.............................................................................149 Metric and Inch (SAE) Fasteners.............................................149 Safety Precautions Maintenance and Repair...................................150 General.....................................................................153 Threaded Fasteners......................................................153 Nomenclature, Threads...................................................153 Strength Identification.................................................154 Cotter (Split) Pins.....................................................154 Fastener Torque Tables..................................................159 Conversion Table........................................................161 tables..........................................................................149 Table 1. Bolts and Screws...................................................155 Table 2. Studs and Nuts.....................................................156 Table 3. Torque Nuts........................................................157 Table 4. Torque Nuts With Nylon Insert......................................158 Table 5. Torque Values for Metric Fasteners*................................159 Table 6. Torque Values for Inch Fasteners*..................................160 Table 7. Conversion Table for Metric and English Units......................161 Table 8. Cotter Pin Dimensional Data........................................162 Table 9. Cotter Pin Dimensional Data........................................163 Table 10. Cotter Pin Dimensional Data.......................................164 Table 11. Cotter Pin Dimensional Data.......................................166 1487040-8000SRM0980-(11-2004)-US-EN.................................................171 toc.............................................................................171 Diagrams....................................................................171 Safety Precautions Maintenance and Repair...................................172 1487042-8000SRM0970-(02-2007)-US-EN.................................................189 toc.............................................................................189 Periodic Maintenance........................................................189 Safety Precautions Maintenance and Repair...................................190 General.....................................................................193 Discharging the Capacitors..............................................193 How to Move Disabled Truck..............................................194 How to Tow Lift Truck...............................................194 How to Put Lift Truck on Blocks.........................................195 How to Raise Load Wheels............................................195 How to Raise Steer Wheel............................................195 How to Raise the Entire Lift Truck..................................196 Safety Procedures When Working Near Mast....................................196 Maintenance Schedule........................................................198 Maintenance Procedures Every 8 Hours or Daily...............................202 Checks With Key Switch Turned OFF.......................................202 Battery.............................................................202 Hydraulic System....................................................203 Tires and Wheels....................................................205 Safety Labels.......................................................205 Overhead Guard......................................................205 Mast, Forks, and Lift Chains........................................205 Reach, Tilt, and Sideshift..........................................207 Forks...............................................................207 Remove..........................................................207 Install.........................................................208 Lift Chain Adjustments..............................................208 Checks With Key Switch Turned ON........................................210 Operation...........................................................210 Instruments and Controls............................................210 Lift System Operation...............................................212 Multifunction Control Handle........................................213 Brake...............................................................213 C470, C471, and G138............................................213 B264............................................................213 Steering System.....................................................214 Maintenance Procedures Every 350 Hours or 2 Months..........................214 Master Drive Unit.......................................................214 Brake...................................................................214 C470, C471, and G138................................................214 B264................................................................214 Hydraulic System........................................................215 Articulation Stop Adjustment............................................215 Adjustment Procedure................................................215 Lift System Operation...................................................216 Forks...............................................................217 Mast................................................................217 Lift Chains.........................................................217 Other Lubrication.......................................................217 Electrical Inspection...................................................217 Fuses...............................................................217 Contactors..........................................................218 Motor Brushes.......................................................218 Maintenance Procedures Every 2000 Hours or Yearly...........................219 Hydraulic System........................................................219 Change Hydraulic Oil................................................219 Change Hydraulic Oil Filter.........................................220 Check Hydraulic Oil Strainer........................................220 Brakes..................................................................220 Maintenance Procedures Every 3000 Hours or Three Years......................220 Traction Motor..........................................................220 Lift and Tilt System Leaks Check............................................221 Lift System.............................................................221 Tilt System.............................................................221 Brakes Adjustment...........................................................222 C470, C471, and G138....................................................222 B264....................................................................222 Battery Maintenance.........................................................223 How to Charge Battery...................................................223 How to Change Battery...................................................224 Tires and Wheels............................................................227 Drive Tire..............................................................227 How to Change Drive Tire................................................227 Tandem Load Wheels......................................................228 Single Load Wheel.......................................................228 Caster Wheels...........................................................229 C470, C471, and G138................................................229 B264................................................................230 Preparation for Storage.....................................................231 Short-Term Storage (1 to 6 months)......................................231 Long-Term Storage (6 months or longer)..................................231 Transporting................................................................231 Loading.................................................................231 Unloading...............................................................232 Preparation for Use.........................................................232 Preparation After Shipment..............................................232 Preparation After Storage...............................................232 tables..........................................................................189 Table 1. Maintenance Schedule...............................................199 Table 2. Articulation Adjustment Chart......................................215 Table 3. Fuses..............................................................218 Table 4. Hydraulic Tank Capacities..........................................219 Table 5. Battery Size Specifications........................................226 Table 6. Tires and Wheels...................................................227 1503619-4500SRM0971-(04-2003)-US-EN.................................................235 toc.............................................................................235 Reach Carriages.............................................................235 Safety Precautions Maintenance and Repair...................................236 General.....................................................................239 Safety Procedures When Working Near Mast....................................239 Description.................................................................241 Reach Assemblies........................................................241 Repair - General............................................................243 Load Backrest Removal and Installation......................................243 Fork Replacement............................................................244 Hook Forks..............................................................244 Reach Assembly Removal and Installation.....................................245 Carriage Load Rollers Removal and Installation..............................246 Side Rollers Disassembly and Assembly.......................................247 Reach Assembly Repair.......................................................247 Reach Assembly Outer Frame..................................................248 Remove..................................................................248 Disassemble.............................................................248 Clean and Inspect.......................................................249 Assemble................................................................249 Install.................................................................249 Remove Without Sideshifter..............................................250 Disassemble Without Sideshifter.........................................252 Clean and Inspect.......................................................252 Assemble Without Sideshifter............................................252 Install Without Sideshifter.............................................253 Single-Reach Scissor Arms...................................................254 Remove and Disassemble..................................................254 Clean and Inspect.......................................................255 Assemble and Install....................................................255 Double-Reach Scissor Arms...................................................259 Remove and Disassemble..................................................259 Clean and Inspect.......................................................261 Assemble and Install....................................................261 Inner Frame Assembly........................................................262 Remove..................................................................262 Disassemble.............................................................265 Clean and Inspect.......................................................266 Assemble................................................................266 Install.................................................................266 Reach Cylinders.............................................................267 Remove..................................................................267 Disassemble.............................................................268 Clean and Inspect.......................................................268 Assemble................................................................269 Install.................................................................269 Tilt Cylinder...............................................................270 Remove..................................................................270 Clean and Inspect.......................................................270 Assemble................................................................270 Sideshift Cylinder..........................................................271 Remove..................................................................271 Clean and Inspect.......................................................271 Reach/Tilt Selector Valve...................................................271 Remove..................................................................271 Disassemble.............................................................271 Clean and Inspect.......................................................272 Assemble................................................................272 Install.................................................................272 Carriage or Reach Assembly Adjustments......................................272 Adjust Wear Plug........................................................272 Adjust Side Rollers.....................................................273 Adjust Thrust Rollers...................................................274 Adjust Reach Cylinders..................................................274 Specifications..............................................................275 Troubleshooting ............................................................279 (NDR030GB, NR045GB, NDR030AE,NR035/040/045AE, NDR030CB, and NR04........279 (W20/30ZR)..............................................................279 tables..........................................................................235 Table 1. General Specifications.............................................275 Table 2. Operating Times N30XMXDR3, N45XMXR3, N30/40XMR2, N25XMD............276 Table 3. Operating Times W20/30ZR...........................................278 1503622-8000SRM0972-(02-2007)-US-EN.................................................283 toc.............................................................................283 Capacities and Specifications...............................................283 Safety Precautions Maintenance and Repair...................................284 SEM Traction Motor Controllers Factory Values and Min/Max Ranges............287 Lift Capacities.............................................................288 Articulation Adjustment.....................................................289 Master Drive Unit Specifications............................................289 Oil Capacities..............................................................289 Lubrication Specifications..................................................290 Hydraulic Systems Specifications............................................290 Reach Carriage Specifications...............................................291 Battery Size Specifications.................................................291 Tire Sizes..................................................................292 Fuses.......................................................................292 Steering Pump Specifications................................................293 Hydraulic Control Valve/Relay Coil Resistance Values........................293 1503623-1900SRM0973-(12-2004)-US-EN.................................................297 toc.............................................................................297 Hydraulic System............................................................297 Safety Precautions Maintenance and Repair...................................298 General.....................................................................301 Description.................................................................301 Control Handle..............................................................302 Description.............................................................302 Control Valve...............................................................303 Description.............................................................303 Trucks Built Before 15 July, 2002...................................303 Trucks Built After 15 July, 2002....................................303 Control Valve-Manual Lowering...........................................303 Trucks Built Before 15 July, 2002...................................303 Trucks Built After 15 July, 2002....................................304 Remove..................................................................304 Install.................................................................304 Check and Adjust........................................................305 Main Relief Valve (N25XMDR3, N30/40XMR3, N50XMA3, N30XMDR3, N45X....305 Main Relief Valve (N30XMXDR3, N45XMXR3).............................306 Auxiliary Relief Valve .............................................306 Lift Pump and Motor.........................................................307 Description.............................................................307 Remove..................................................................307 Install.................................................................309 Disassemble.............................................................309 Assemble................................................................310 Steering Pump...............................................................310 Hydraulic Tank..............................................................310 Description.............................................................310 Remove and Disassemble..................................................311 Assemble and Install....................................................311 Troubleshooting.............................................................312 tables..........................................................................297 Table 1. Hydraulic Tank Capacities..........................................310 1503624-1600SRM0974-(07-2002)-US-EN.................................................321 toc.............................................................................321 Steering System.............................................................321 Safety Precautions Maintenance and Repair...................................322 General.....................................................................325 Description.................................................................325 Steering Control Unit Assembly..............................................326 Description.............................................................326 Remove..................................................................326 Steering Control Unit.......................................................326 Description.............................................................326 Operation...............................................................326 Remove..................................................................327 Repair..................................................................327 Disassemble (Before May 2002).......................................327 Disassemble (After May 2002)........................................328 Clean...............................................................330 Reassemble (Before May 2002)........................................331 Reassemble (After May 2002).........................................331 Install.................................................................332 Steering Pump and Motor Assembly............................................332 Description.............................................................332 Pump and Motor..........................................................333 Remove and Disassemble..............................................333 Assemble and Install................................................333 Pump....................................................................334 Remove..............................................................334 Install.............................................................335 Disassemble.........................................................335 Assemble............................................................336 Axle Assembly Repair........................................................336 General.................................................................336 Traction Motor..........................................................336 Description.........................................................336 Remove..............................................................336 Install.............................................................337 Master Drive Unit.......................................................337 Description.........................................................337 Remove Chain-Steered MDU............................................337 Install.............................................................338 Hydraulic Steering Motor................................................338 Description.........................................................338 Remove..............................................................339 Install.............................................................340 Caster Wheels...........................................................340 Description.........................................................340 Caster Replacement..................................................340 Wheel Replacement...................................................341 Axle Weldment...........................................................342 Remove..............................................................342 Install.............................................................342 Check and Adjust........................................................343 Remove Air From Steering System.....................................343 Check Steering Chain................................................343 Check Articulation Stop Adjustment..................................344 Steering Pressure...................................................344 Troubleshooting.............................................................346 tables..........................................................................321 Table 1. Articulation Adjustment Chart......................................344 1503625-0100SRM0975-(08-2001)-US-EN.................................................351 toc.............................................................................351 Frame.......................................................................351 Safety Precautions Maintenance and Repair...................................352 General.....................................................................355 Description.................................................................355 Repairs - General...........................................................355 Covers, Panels, and Plates..................................................356 Replace Load Wheels.....................................................360 Overhead Guard Repair.......................................................361 Changes to Overhead Guard...............................................361 Remove..................................................................361 Install.................................................................362 Painting Instructions.......................................................363 Safety Labels Replacement...................................................366 tables..........................................................................351 Table 1. Unit and Model Numbers.............................................355 1503627-2200SRM0977-(08-2005)-US-EN.................................................369 toc.............................................................................369 SEM Traction Motor Controller...............................................369 Safety Precautions Maintenance and Repair...................................370 SEM Traction Motor Controller...............................................373 Description/Features....................................................373 Remove..................................................................373 Test....................................................................374 Install.................................................................374 1307 Programmer Handset.....................................................375 Description/Features....................................................375 SCROLL DISPLAY Keys.....................................................376 CHANGE VALUE Keys.......................................................376 MORE INFO Key...........................................................376 Operation...............................................................376 Connecting Handset to Traction Motor Controller.....................376 Disconnecting Handset From Traction Motor Controller................377 Programmer Self Test................................................377 Operating Modes.........................................................378 Program Menu........................................................378 Test Menu...........................................................378 Diagnostics Menu....................................................379 Diagnostic History..................................................380 Special Program Menu................................................380 Programming the Traction Motor Controller - 1307 Handset....................380 1311 Programmer Handset.....................................................383 Description/Features....................................................383 Menu Navigation Key.................................................383 Data Increase/Decrease Key..........................................384 Bookmark Keys.......................................................384 Operation...............................................................384 Connecting Handset to Traction Motor Controller.....................384 Disconnecting the Handset From the Traction Motor Controller........385 Main Menu Selections....................................................385 Program Menu........................................................385 Monitor Menu........................................................386 Faults Menu.........................................................386 Functions menu......................................................387 Information Menu....................................................388 Programmer Setup Menu...............................................388 Programming the Traction Motor Controller - 1311 Handset....................388 Troubleshooting.............................................................389 Status LED Diagnostics..................................................389 Diagnostics Menu........................................................390 Test Menu...............................................................400 tables..........................................................................369 Table 1. Program Menu.......................................................378 Table 2. Test Menu..........................................................378 Table 3. Dash Display Drive Mode Inputs.....................................379 Table 4. Diagnostics and Diagnostic History Display.........................379 Table 5. Special Program Menu...............................................380 Table 6. Program Menu Range and Default Values..............................381 Table 7. Status LED Fault Codes.............................................390 1503628-2200SRM0978-(05-2005)-US-EN.................................................407 toc.............................................................................407 Electrical System...........................................................407 Safety Precautions Maintenance and Repair...................................408 General.....................................................................413 Component Repair and Testing - General......................................414 Contactor Panel Assembly....................................................414 Description/Features....................................................414 Remove..................................................................414 Install.................................................................415 Contactors..................................................................415 Description/Features....................................................415 Auxiliary Switch........................................................416 Testing.................................................................416 Remove..................................................................417 Install.................................................................417 EE Contactors...........................................................417 Fuses.......................................................................419 Relays......................................................................420 Description/Features....................................................420 Enable Relay............................................................420 Hourmeter Relay.........................................................420 Lift/Lower Relay (Trucks Built After 1 August 2002).....................420 Coil Testing............................................................420 Contact Testing.........................................................421 Remove and Install......................................................421 Height Proximity Switch.....................................................422 Remove..................................................................422 Test....................................................................422 Install.................................................................423 Adjust..................................................................423 Key Switch..................................................................423 Description.............................................................423 Remove..................................................................423 Install.................................................................424 Battery Disconnect Switch...................................................424 Description.............................................................424 Remove..................................................................424 Install.................................................................424 Proportional Electro-Hydraulic Control Valves...............................425 Manual Lowering.........................................................425 Trucks Built Before 1 August, 2002..................................425 Trucks Built After 1 August, 2002...................................426 Operation...............................................................426 Repair..................................................................426 Carriage Valve Assembly and Selector Valves ................................427 Test/Remove/Install.....................................................427 Multifunction Control Handle................................................428 Description/Features....................................................428 Remove..................................................................428 Disassemble.............................................................429 Tools Required......................................................429 Assemble................................................................431 Install.................................................................432 Shelf Height Selector.......................................................432 Description/Features....................................................432 Shelf Height Selector...............................................432 Power On, Start Up..................................................432 Programming.............................................................433 Field Program Mode..................................................433 Enter Shelf Level...................................................433 Set Shelf Level.....................................................433 Quick Pick Level Keys...............................................433 Set Minimum Lift Speed..............................................433 Set Minimum Lower Speed.............................................434 Changing the 3-Digit Security Code..................................434 Factory Program Mode................................................434 Calibrate Lift......................................................434 Set Options.........................................................434 Control Zone........................................................435 Deadband............................................................435 Reset User Code.....................................................435 Clear All...........................................................435 Show All Levels.....................................................436 Set LCD Bias........................................................436 Show Analog.........................................................436 External Inputs.....................................................436 System Errors...........................................................436 Main Interface Board (MIB) Adjustments..................................436 Function 32 Hydraulic Potentiometer - Set-Up........................437 Function 02 Lift Minimum Rate.......................................437 Function 04 Lower Minimum Rate......................................437 Function 59 Hydraulic Lift Function - Stopping Rate.................437 Function 61 Hydraulic Lower Function - Stopping Rate................437 Main Interface Board (MIB)..................................................437 Description/Features....................................................437 Operation...............................................................438 LED Display.............................................................438 MIB, Remove.............................................................439 MIB J-Connector, Repair.................................................440 Inspect.............................................................440 MIB, Install............................................................441 Main Interface Board (MIB) Setup Procedures.................................441 General.................................................................441 Default Values..........................................................442 Checking Model Code, Software Version, and Setup Status.................442 MIB Generation II Setup Procedure.......................................442 Entering the Setup Mode.............................................442 Editing Settings....................................................442 Changing the Setting Values.........................................442 Entering Text.......................................................442 System Information and Fault Log....................................442 Passwords...........................................................443 Defaults............................................................443 Exit and Save.......................................................443 Parameters..........................................................443 Top Level Menu Items................................................444 Options.........................................................444 Handle Deadband.................................................444 Lift/Lower......................................................444 Speeds..........................................................445 Auxiliary.......................................................445 Max Speed and Low End Adjustments.......................................445 Customizing MIB Functions...............................................446 MIB Status, Warning, and Fault Codes........................................460 General.................................................................460 Troubleshooting Charts..................................................460 Blank or Undefined Code Conditions..........................................462 Status Codes................................................................466 Warning Codes...............................................................470 Fault Codes.................................................................474 SEM Traction Motor Controller...............................................483 Description/Features....................................................483 Remove..................................................................483 Test....................................................................484 Install.................................................................484 1307 Programmer Handset.....................................................486 Description/Features....................................................486 SCROLL DISPLAY Keys.....................................................486 CHANGE VALUE Keys.......................................................486 MORE INFO Key...........................................................486 Operation...............................................................487 Connecting Handset to Traction Motor Controller.....................487 Disconnecting Handset from Traction Motor Controller................487 Programmer Self Test................................................487 Operating Modes.........................................................488 Program Menu........................................................488 Test Menu...........................................................489 Diagnostics Menu....................................................489 Diagnostic History..................................................490 Special Program Menu................................................490 Programming the Traction Motor Controller - 1307 Handset....................491 1311 Programmer Handset.....................................................493 Description/Features....................................................493 Menu Navigation Key.................................................494 Data Increase/Decrease Key..........................................494 Bookmark Keys.......................................................495 Operation...............................................................495 Connecting Handset to Traction Motor Controller.....................495 Disconnecting the Handset From the Traction Motor Controller........495 Main Menu Selections....................................................495 Program Menu........................................................495 Monitor Menu........................................................496 Faults Menu.........................................................496 Functions menu......................................................497 Information Menu....................................................498 Programmer Setup Menu...............................................498 Programming the Traction Motor Controller - 1311 Handset....................498 Troubleshooting.............................................................499 Status LED Diagnostics..................................................499 Programmer Diagnostics..................................................500 Diagnostics Menu........................................................501 Test Menu...............................................................510 Dash Display Assembly.......................................................513 Description and Features................................................513 Operation...............................................................514 Battery Indicator...................................................515 Remove..................................................................515 Install.................................................................516 Voltage Selection.......................................................516 Dash Display, Adjust....................................................516 Battery Indicator Profile Settings......................................517 Troubleshooting.........................................................517 Inoperative Dash Display Assembly...................................517 Inoperative Drive Mode Selection....................................517 Troubleshooting the Dash Display With a Programmer Handset..........517 Troubleshooting Without a Programmer Handset........................518 No Warnings or Faults Displayed.....................................518 Lift Interrupt......................................................519 Lost MIB Signal Displayed...........................................519 Hourmeter Input.....................................................519 tables..........................................................................407 Table 1. Contactor Coil Voltages............................................416 Table 2. Fuses..............................................................419 Table 3. Hydraulic Control Valve/Relay Coil Resistance Values...............421 Table 4. OPTS Bits..........................................................435 Table 5. Truck Unit and Model Codes.........................................442 Table 6. MIB Function Code Values for N30XMR3 Software 06/01/01 ............446 Table 7. MIB Function Code Values for N40XMR3 06/01/01 to 01/14/............447 Table 8. MIB Function Code Values for N25XMDR3..............................448 Table 9. MIB Function Code Values for N50XMA3...............................449 Table 10. MIB Function Code Values for N45XMR3..............................450 Table 11. MIB Function Code Values for N30XMDR3.............................450 Table 12. MIB Function Code Values for N45XMXR3 Mast Full Height............451 Table 13. MIB Function Code Values for N45XMXR3 Mast Full Height............451 Table 14. MIB Function Code Values for N30XMXDR Mast Full Height............452 Table 15. MIB Function Code Values for N30XMXDR Mast Full Height............452 Table 16. MIB Software 01/14/02 to 03/27/02 ................................453 Table 17. MIB Software 01/14/02 to 03/27/02 NXMR3 and NXMXR3 (G1............455 Table 18. MIB Software Post 03/27/02 NXMR3, NXMDR3 C470 ....................456 Table 19. MIB Software Post 03/27/02 NXMR3, NXMDR3 (G138) and N3............457 Table 20. NXMXDR3, NXMXR3 (B264)............................................458 Table 21. Program Menu......................................................488 Table 22. Test Menu.........................................................489 Table 23. Dash Display Drive Mode Inputs....................................489 Table 24. Diagnostic and Diagnostic History Display.........................490 Table 25. Special Program Menu..............................................491 Table 26. Program Menu Range and Default Values.............................492 Table 27. Status LED Fault Codes............................................500 Table 28. Dash Display Drive Mode Inputs....................................518 Table 29. Dash Display Drive Mode Test Voltages.............................518 Table 30. Dash Display Status/Warning/Fault Test Voltages...................519 1503628-2200SRM0978-(10-2004)-US-EN.................................................523 toc.............................................................................523 Electrical System...........................................................523 Safety Precautions Maintenance and Repair...................................524 General.....................................................................529 Component Repair and Testing - General......................................530 Contactor Panel Assembly....................................................530 Description/Features....................................................530 Remove..................................................................530 Install.................................................................531 Contactors..................................................................531 Description/Features....................................................531 Auxiliary Switch........................................................532 Testing.................................................................532 Remove..................................................................533 Install.................................................................533 EE Contactors...........................................................533 Fuses.......................................................................535 Relays......................................................................536 Description/Features....................................................536 Enable Relay............................................................536 Hourmeter Relay.........................................................536 Lift/Lower Relay (Trucks Built After 1 August 2002).....................536 Coil Testing............................................................536 Contact Testing.........................................................537 Remove and Install......................................................537 Height Proximity Switch.....................................................538 Remove..................................................................538 Test....................................................................538 Install.................................................................539 Adjust..................................................................539 Key Switch..................................................................539 Description.............................................................539 Remove..................................................................539 Install.................................................................540 Battery Disconnect Switch...................................................540 Description.............................................................540 Remove..................................................................540 Install.................................................................540 Proportional Electro-Hydraulic Control Valves...............................541 Manual Lowering.........................................................541 Trucks Built Before 1 August, 2002..................................541 Trucks Built After 1 August, 2002...................................542 Operation...............................................................542 Repair..................................................................542 Carriage Valve Assembly and Selector Valves ................................543 Test/Remove/Install.....................................................543 Multifunction Control Handle................................................543 Description/Features....................................................543 Remove..................................................................544 Disassemble.............................................................545 Tools Required......................................................545 Assemble................................................................547 Install.................................................................547 Shelf Height Selector.......................................................548 Description/Features....................................................548 Shelf Height Selector...............................................548 Power On, Start Up..................................................548 Programming.............................................................548 Field Program Mode..................................................548 Enter Shelf Level...................................................548 Set Shelf Level.....................................................549 Quick Pick Level Keys...............................................549 Set Minimum Lift Speed..............................................549 Set Minimum Lower Speed.............................................549 Changing the 3-Digit Security Code..................................549 Factory Program Mode................................................550 Calibrate Lift......................................................550 Set Options.........................................................550 Control Zone........................................................551 Deadband............................................................551 Reset User Code.....................................................551 Clear All...........................................................551 Show All Levels.....................................................551 Set LCD Bias........................................................551 Show Analog.........................................................552 External Inputs.....................................................552 System Errors...........................................................552 Main Interface Board (MIB) Adjustments..................................552 Function 32 Hydraulic Potentiometer - Set-Up........................552 Function 02 Lift Minimum Rate.......................................552 Function 04 Lower Minimum Rate......................................553 Function 59 Hydraulic Lift Function - Stopping Rate.................553 Function 61 Hydraulic Lower Function - Stopping Rate................553 Main Interface Board (MIB)..................................................553 Description/Features....................................................553 Operation...............................................................553 LED Display.............................................................554 MIB, Remove.............................................................554 MIB J-Connector, Repair.................................................556 Inspect.............................................................556 MIB, Install............................................................557 Main Interface Board (MIB) Setup Procedures.................................557 General.................................................................557 Default Values..........................................................557 Checking Model Code, Software Version, and Setup Status.................558 MIB Generation II Setup Procedure.......................................558 Entering the Setup Mode.............................................558 Editing Settings....................................................558 Changing the Setting Values.........................................558 Entering Text.......................................................558 System Information and Fault Log....................................558 Passwords...........................................................559 Defaults............................................................559 Exit and Save.......................................................559 Parameters..........................................................559 Top Level Menu Items................................................560 Options.........................................................560 Handle Deadband.................................................560 Lift/Lower......................................................560 Speeds..........................................................561 Auxiliary.......................................................561 Max Speed and Low End Adjustments.......................................561 Customizing MIB Functions...............................................562 MIB Status, Warning, and Fault Codes........................................576 General.................................................................576 Troubleshooting Charts..................................................576 Blank or Undefined Code Conditions..........................................578 Status Codes................................................................582 Warning Codes...............................................................586 Fault Codes.................................................................590 SEM Traction Motor Controller...............................................599 Description/Features....................................................599 Remove..................................................................599 Test....................................................................600 Install.................................................................600 1307 Programmer Handset.....................................................602 Description/Features....................................................602 SCROLL DISPLAY Keys.....................................................602 CHANGE VALUE Keys.......................................................602 MORE INFO Key...........................................................602 Operation...............................................................603 Connecting Handset to Traction Motor Controller.....................603 Disconnecting Handset from Traction Motor Controller................603 Programmer Self Test................................................603 Operating Modes.........................................................604 Program Menu........................................................604 Test Menu...........................................................605 Diagnostics Menu....................................................605 Diagnostic History..................................................606 Special Program Menu................................................606 Programming the Traction Motor Controller - 1307 Handset....................607 1311 Programmer Handset.....................................................609 Description/Features....................................................609 Menu Navigation Key.................................................610 Data Increase/Decrease Key..........................................611 Bookmark Keys.......................................................611 Operation...............................................................611 Connecting Handset to Traction Motor Controller.....................611 Disconnecting the Handset From the Traction Motor Controller........611 Main Menu Selections....................................................612 Program Menu........................................................612 Monitor Menu........................................................612 Faults Menu.........................................................613 Functions menu......................................................613 Information Menu....................................................614 Programmer Setup Menu...............................................614 Programming the Traction Motor Controller - 1311 Handset....................614 Troubleshooting.............................................................615 Status LED Diagnostics..................................................616 Programmer Diagnostics..................................................616 Diagnostics Menu........................................................617 Test Menu...............................................................626 Dash Display Assembly.......................................................629 Description and Features................................................629 Operation...............................................................630 Battery Indicator...................................................631 Remove..................................................................631 Install.................................................................632 Voltage Selection.......................................................632 Dash Display, Adjust....................................................632 Battery Indicator Profile Settings......................................633 Troubleshooting.........................................................633 Inoperative Dash Display Assembly...................................633 Inoperative Drive Mode Selection....................................633 Troubleshooting the Dash Display With a Programmer Handset..........634 Troubleshooting Without a Programmer Handset........................634 No Warnings or Faults Displayed.....................................635 Lift Interrupt......................................................635 Lost MIB Signal Displayed...........................................635 Hourmeter Input.....................................................635 tables..........................................................................523 Table 1. Contactor Coil Voltages............................................532 Table 2. Fuses..............................................................535 Table 3. Hydraulic Control Valve/Relay Coil Resistance Values...............537 Table 4. OPTS Bits..........................................................550 Table 5. Truck Unit and Model Codes.........................................558 Table 6. MIB Function Code Values for N30XMR3 Software 06/01/01 ............562 Table 7. MIB Function Code Values for N40XMR3 06/01/01 to 01/14/............563 Table 8. MIB Function Code Values for N25XMDR3..............................564 Table 9. MIB Function Code Values for N50XMA3...............................565 Table 10. MIB Function Code Values for N45XMR3..............................566 Table 11. MIB Function Code Values for N30XMDR3.............................566 Table 12. MIB Function Code Values for N45XMXR3 Mast Full Height............567 Table 13. MIB Function Code Values for N45XMXR3 Mast Full Height............567 Table 14. MIB Function Code Values for N30XMXDR Mast Full Height............568 Table 15. MIB Function Code Values for N30XMXDR Mast Full Height............568 Table 16. MIB Software 01/14/02 to 03/27/02 ................................569 Table 17. MIB Software 01/14/02 to 03/27/02 NXMR3 and NXMXR3 (G1............571 Table 18. MIB Software Post 03/27/02 NXMR3, NXMDR3 C470 ....................572 Table 19. MIB Software Post 03/27/02 NXMR3, NXMDR3 (G138) and N3............573 Table 20. NXMXDR3, NXMXR3 (B264)............................................575 Table 21. Program Menu......................................................604 Table 22. Test Menu.........................................................605 Table 23. Dash Display Drive Mode Inputs....................................605 Table 24. Diagnostic and Diagnostic History Display.........................605 Table 25. Special Program Menu..............................................606 Table 26. Program Menu Range and Default Values.............................608 Table 27. Status LED Fault Codes............................................616 Table 28. Dash Display Drive Mode Inputs....................................634 Table 29. Dash Display Drive Mode Test Voltages.............................634 Table 30. Dash Display Status/Warning/Fault Test Voltages...................635 1523820-0630SRM1022-(11-2006)-US-EN.................................................639 toc.............................................................................639 Master Drive Unit...........................................................639 Safety Precautions Maintenance and Repair...................................640 HFK400 Master Drive Unit....................................................643 General.................................................................643 Description.............................................................643 Drive Unit Maintenance and Repair.......................................644 Remove..............................................................644 Install.............................................................645 Disassemble.........................................................646 Assemble............................................................649 Troubleshooting.........................................................657 GK Master Drive Unit........................................................659 General.................................................................659 Description.............................................................659 Maintenance and Repair..................................................660 Install.................................................................661 Assemble................................................................661 Mounting Electric Motor.............................................662 Pivoted Connection - Geared Steering................................662 Disassemble.............................................................662 Troubleshooting.........................................................663 tables..........................................................................639 Table 1. Tooth Contact Pattern..............................................654 Unlock-1503626-1800SRM0976-(05-2001)-US-EN..........................................667
HYSTER C470 SERVICE MANUAL – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the SAME MANUAL used by the dealerships to diagnose your vehicle
- No waiting for couriers / posts as this is a PDF manual and you can download it within 2 minutes time once you make the payment.
- Your payment is all safe and the delivery of the manual is INSTANT – You will be taken to the DOWNLOAD PAGE.
- So have no hesitations whatsoever and write to us about any queries you may have : heydownloadss @gmail.com
S.V
