Hyster C174 (R30XMS) Service Manual - Image 2

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Hyster C174 (R30XMS) Service Manual

$30.00

Type Of Manual: Service Manual
Number of Pages: 598
Size: 33.2MB
Format: PDF

Category: Hyster Service Manual PDF

Model List:
- C174 (R30XMS)

1. INTRODUCTION
2. GENERAL
3. LEAD-ACID BATTERIES
4. SPECIFIC GRAVITY
5. THE CHEMICAL REACTION IN A CELL
6. ELECTRICAL TERMS
7. HOW TO SELECT THE BATTERY
8. VOLTAGE OF A BATTERY
9. THE BATTERY AS A COUNTERWEIGHT
10. BATTERY RATINGS
11. Kilowatt-Hours
12. BATTERY MAINTENANCE
13. SAFETY PROCEDURES
14. MAINTENACE RECORDS
15. THE NEW BATTERY
16. HOW TO CLEAN THE BATTERY
17. HOW TO ADD WATER
18. THE HYDROMETER
19. BATTERY TEMPERATURE
20. CHARGING THE BATTERY
21. Types Of Battery Charges
22. Methods Of Charging
23. Troubleshooting The Charger
24. How To Know When The Battery Is Fully Charged
25. WHERE TO CHARGE THE BATTERIES
26. Equipment Needed
27. BATTERY CONNECTORS
28. BATTERY CARE
29. INTRODUCTION
30. General
31. Description
32. Removal And Disassembly
33. Covers, Panels And Plates
34. R30EA-FS Caster And Caser Wheel
35. Description
36. Replacing Caster
37. Replacing Caster Wheels
38. Painting Instructions
39. Label Replacement
40. INTRODUCTION
41. GENERAL
42. DESCRIPTION
43. REMOVAL AND DISASSEMBLY
44. COVERS, PANELS AND PLATES
45. CASTER AND CASTER WHEEL
46. Description
47. Replace The Caster
48. Replace the Caster Wheels
49. PAINTING INSTRUCTIONS
50. LABEL REPLACEMENT
51. INTRODUCTION
52. DESCRIPTION
53. OPERATION
54. Flow Control Valve
55. Relief Valve
56. REPAIRS
57. REMOVAL
58. DISASSEMBLY
59. CLEANING
60. INSPECTION
61. ASSEMBLY
62. INSTALLATION
63. CHECKS AND ADUSTMENTS
64. CHECK THE OUTPUT OF THE PUMP
65. CHECK FOR AIR IN THE HYDRAULIC SYSTEM
66. TROUBLESHOOTING
67. DC Motor Maintenance
68. Safety Precautions Maintenance and Repair
69. General
70. Brush and Commutator Inspection
71. Hydraulic Pump Motor and Traction Motor
72. Steering Pump Motor
73. Normal Commutator Surface
74. Commutator Problems
75. Brush Replacement
76. Stoning the Commutator
77. Motors Repair
78. Disassemble
79. Traction Motor and Hydraulic Pump Motor
80. Steering Pump Motor
81. Assemble
82. Traction Motor and Hydraulic Pump Motor
83. Steering Pump Motor
84. Brush Alignment, Traction and Hydraulic Motors
85. Tests for Damaged Field and Armature
86. Test for an Open Circuit in Armature
87. Test for Short Circuit in One Armature Winding
88. Test for Short Circuit to Armature Shaft
89. Test for Open Circuit in Field Coil
90. Test for Short Circuit in Field Coil
91. Test for Short Circuit between Field and Motor Case
92. Brush Holder Test
93. Troubleshooting
94. Table 1. Normal Commutator Surfaces
95. Table 2. Commutator Problems
96. Table 3. Brush Wear Replacement Guide
97. INTRODUCTION
98. GENERAL
99. DESCRIPTION
100. REMOVAL
101. Mount Type A
102. Mount Type B (A1.00-1.50XL, N40-50EA/ER, N50FA, N30-45FR, R30E/EA/EF/ES Only)
103. Mount Type B (R30DH Only)
104. DISASSEMBLY
105. ASSEMBLY
106. General
107. Installing The Spiral Bevel Pinion
108. Installing Thr Spiral Bevel Gear
109. INSTALLATION
110. Mount Type A
111. Mount Type B (A1.00-1.50XL, N40-50EA/ER, N50FA, N30-45FR, R30E/EA/EF/ES Only)
112. Mount Type B (R30DH Only)
113. CHECKS AND ADJUSTMENTS
114. ADJUST THE BACKLASH AND TOOTH CONTACT
115. ADJUST BEARING CONTACT
116. TROUBLESHOOTING
117.
118.
118.1. Power Steering
118.2. Safety Precautions Maintenance and Repair
118.3. General
118.4. EPS III
118.5. Description
118.6. EPS III
118.7. APS System
118.8. Checks and Adjustments
118.9. General
118.10. Checks, EPS III
118.11. Dipswitches, EPS III
118.12. LED Indicators, EPS III
118.13. Check Steering System for Correct Operation, EPS III
118.14. Check Slow Travel Speed, EPS III
118.15. Check High Lift Traction Shutoff, EPS III
118.16. Checks, APS
118.17. Dipswitches, APS
118.18. LED Indicators, APS
118.19. Adjustments
118.20. General
118.21. Steer Motor With Steering Chain Replacement, EPS III
118.22. Steer Motor With Steering Gear Replacement, APS
118.23. Return-to-Center Steering System
118.24. Tach Generator Steering System, EPS III
118.25. Slow Travel Adjustment, EPS III
118.26. Return-to-Center and Multiturn System, APS
118.27. Steering Chain Adjustment, EPS III
118.28. Repairs
118.29. RTC Steering System, EPS III
118.30. Command Potentiometer Replacement, EPS III
118.31. TGS System, EPS III
118.32. Tach Generator Replacement, EPS III
118.33. Feedback Potentiometer Replacement, EPS III
118.34. ECM Replacement, EPS III
118.35. Steer Motor Assembly and Steering Chain Replacement, EPS III
118.36. Typical Operating Voltages, EPS III
118.37. Steering Proximity Switch and Centering Proximity Switch, APS
118.38. Troubleshooting
118.39. EPS III
118.40. Table 1. LED Indicators
118.41. Table 2. Sensitivity Adjustment
118.42. Table 3. Typical Operating Voltages
119.
119.1. INTRODUCTION
119.1.1. GENERAL
119.1.2. DESCRIPTION AND OPERATION
119.2. REPAIRS
119.2.1. ELECTRIC BRAKE
119.2.2. BRAKE SWITCH
119.3. TROUBLESHOOTING
120.
120.1. INTRODUCTION
120.1.1. GENERAL
120.2. DESCRIPTION AND OPERATION
120.2.1. Electric Brake
120.3. REPAIRS
120.3.1. Electric Brake
120.4. TROUBLESHOOTING
121.
121.1. INTRODUCTION
121.1.1. Description
121.2. REPAIRS
121.2.1. Hydraulic Pump
121.2.2. Control Valve
121.3. CHECKS AND ADJUSTMENTS
121.3.1. Relief Valve Adjustments
121.4. TROUBLESHOOTING
121.4.1. Hydraulic Pump
121.4.2. Control Valve
121.5. SPECIFICATIONS
122.
123.
123.1. INTRODUCTION
123.1.1. GENERAL
123.2. DESCRIPTION
123.2.1. GENERAL
123.2.2. STEERING COLUMN GAUGES, METERS AND INDICATORS
123.2.3. LED DISPLAY PANEL
123.2.4. LX SERIES DISPLAY PANEL
123.2.5. ZX SERIES DISPLAY PANELS
123.3. CHECKS AND ADJUSTMENTS
123.3.1. GENERAL
123.4. REPLACEMENT
123.4.1. GENERAL
123.4.2. METER REPLACEMENT
123.4.3. SENDER REPLACEMENT
123.4.4. DISPLAY PANEL
123.4.5. DISPLAY PANELS FOR THE EV – 100/200ZX MOTOR CONTROLLERS, COLUMN MOUNT
123.4.6. DISPLAY PANELS FOR THE EV-100/200ZX MOTOR CONTROLLERS, DASH MOUNT
123.5. SPECIFICATIONS
123.6. TROUBLESHOOTING
124.
125.
125.1. INTRODUCTION
125.1.1. General
125.1.2. Operation
125.2. CHECKS AND ADJUSTMENTS
125.2.1. General
125.2.2. Adjustments
126.
126.1. INTRODUCTION
126.1.1. GENERAL
126.1.2. STEERING MECHANISM
126.1.3. REPLACE GUIDANCE SWITCH, INDICATOR AND ALARM
126.1.4. REPLACE MDU POTENTIOMETER
126.1.5. REPLACE THE ECM
126.1.6. REPLACE THE STEERING CONTACTOR
126.1.7. REPLACE THE GEARMOTOR ASSEMBLY AND STEERING CHAIN
126.1.8. REPLACE THE SENSORS
127.
128.
128.1. INTRODUCTION
128.1.1. GENERAL
128.1.2. INDICATORS WITH METER MOVEMENT
128.1.3. BATTERY INDICATORS WITH LCD OR LED DISPLAYS
128.2. CHECKS AND ADJUSTMENTS
128.2.1. BATTERY INDICATORS WITHOUT LIFT INTERRUPT, EARLY MODELS
128.2.2. BATTERY INDICATORS WITH LIFT INTERRUPT, EARLY MODELS
128.2.3. BATTERY INDICATORS WITHOUT LIFT INTERRUPT, LATER MODELS
128.2.4. BATTERY INDICATORS WITH LIFT INTERRUPT, LATER MODELS
128.2.5. LED DISPLAY WITH LIFT INTERRUPT
128.2.6. CHECKING CURTIS 933-1 METER
128.2.7. ADJUSTMENT OF CURTIS 933-1 METER
128.2.8. ADJUSTMENT OF SEVCON POWERGAUGE
128.3. CURTIS DASH DISPLAY ASSEMBLY
128.3.1. Description/Features
128.3.2. Operation
128.3.3. Testing
128.4. REPAIRS
128.4.1. BATTERY INDICATORS
128.4.2. CONTROLLER FOR THE BATTERY INDICATOR
128.4.3. DISPLAY PANEL COMPONENTS
128.4.4. REPLACING SEM DISPLAY PANEL
128.4.5. SEM DISPLAY PANEL REMOVAL
129.
130.
130.1. INTRODUCTION
130.1.1. GENERAL
130.1.2. MAST WELDMENTS
130.1.3. CARRIAGES
130.2. VISTA TWO-STAGE MAST
130.2.1. DESCRIPTION
130.2.2. OPERATION
130.3. VISTA THREE-STAGE MAST
130.3.1. DESCRIPTION
130.3.2. OPERATION
131.
131.1. INTRODUCTION
131.1.1. GENERAL
131.1.2. DESCRIPTION
131.2. REPAIRS
131.2.1. MAIN CYLINDER – DISASSEMBLY
131.2.2. MAIN CYLINDER – ASSEMBLY
131.2.3. FREE-LIFT CYLINDER – DISASSEMBLY
131.2.4. FREE-LIFT CYLINDER – ASSEMBLY
131.3. TROUBLESHOOTING
132.
132.1. INTRODUCTION
132.1.1. General
132.2. SAFETY PROCEDURES
132.3. LOAD BACKREST EXTENSION, CARRIAGE, LOAD ROLLERS, SIDE ROLLERS AND FORKS
132.3.1. Load Backrest Extension – Removal And Installation
132.3.2. Carriage Assembly – Removal And Installation
132.3.3. Carriage Load Rollers – Removal And Installation
132.3.4. Side Rollers – Disassembly And Assembly
132.3.5. Fork Replacement
132.4. TWO-STAGE MAST ASSEMBLY
132.4.1. Two-Stage Mast Assembly – Removal
132.4.2. Cleaning And Inspection
132.4.3. Lift Cylinders – Removal And Installation
132.4.4. Inner Mast Assembly – Removal And Installation
132.4.5. Hoses – Replace
132.4.6. Hoses And Cable Sheaves – Replace
132.4.7. Two-Stage Lift Chains
132.4.8. Two-Stage Chain Sheave – Removal And Installation
132.4.9. Load Rollers And Wear Plugs – Removal And Installation
132.4.10. Two-Stage Mast Assembly – Installation
132.5. THREE-STAGE MAST ASSEMBLY
132.5.1. Three-Stage Mast Assembly – Removal
132.5.2. Cleaning And Inspection
132.5.3. Free-Lift Cylinder – Removal And Installation
132.5.4. Inner And Intermediate Mast Assemblies – Removal And Installation
132.5.5. Hoses – Replace
132.5.6. Hose And Cable Sheaves – Replace
132.5.7. Three-Stage Lift Chains – Removal And Installation
132.5.8. Three-Stage Chain Sheaves – Diassembly And Assembly
132.5.9. Load Rollers And Wear Plugs – Removal And Installation
132.5.10. Three-Stage Mast Assembly – Installation
132.6. CHECKS AND ADJUSTMENTS
132.6.1. Check The Operation Of The Mast
132.6.2. Check For Leaks In The Hydraulic System
132.6.3. Check Lift Chains
132.6.4. Mast Adjustments
132.6.5. Carriage Adjustments
133.
134.
134.1. INTRODUCTION
134.1.1. GENERAL
134.1.2. HOW TO MOVE A DISABLED LIFT TRUCK
134.1.3. How To Tow The Lift Truck
134.1.4. HOW TO PUT A LIFT TRUCK ON BLOCKS
134.1.5. How To Raise Drive Tire
134.1.6. How To Raise Load Wheels
134.2. MAINTENANCE SCHEDULE
134.3. MAINTENANCE PROCEDURES- EVERY 8 HOURS OR DAILY
134.3.1. HOW TO MAKE CHECKS WITH KEY SWITCH OFF
134.3.2. HOW TO MAKE CHECKS WITH THE KEY SWITCH ON
134.4. EVERY 350 HOURS OR TWO MONTHS
134.4.1. HYDRAULIC TANK BREATHER
134.4.2. ELECTRICAL INSPECTION
134.4.3. SAFETY LABELS
134.4.4. CHECK FOR LEAKS IN THE LIFT SYSTEM
134.4.5. LIFT CHAINS
134.5. EVERY 2000 HOURS OR YEARLY
134.5.1. MASTER DRIVE UNIT
134.5.2. STEERING CHAIN
134.5.3. WHEELS AND BEARINGS
134.5.4. HOW TO CHANGE THE HYDRAULIC OIL AND FILTER
134.5.5. ELECTRICAL CABLE SHEAVES
134.5.6. PALLET CLAMP
134.5.7. LIMIT SWITCH ROLLERS AND OTHER LUBRICATION
134.6. GENERAL PROCEDURES
134.6.1. HOW TO CHARGE THE BATTERY
134.6.2. HOW TO CHANGE THE BATTERY
134.6.3. HOW TO CHANGE WHEELS AND TIRES
134.7. BATTERY SPECIFICATIONS
135.
135.1. BATTERY SPECIFICATIONS
135.2. TRANSISTOR CONTROLLER ADJUSTMENT POINTS
135.3. EV100 TRACTION CARD SETTINGS
135.4. MASTER DRIVE UNIT
135.5. SYSTEM II ELECTRONIC CONTROL MODULE (ELECTRIC POWER STEERING)
135.6. TERMINAL AND PIN ARRANGEMENTS FOR THE EV100 CONTROL CARD
135.7. TERMINAL AND PIN ARRANGEMENTS FOR THE CURTIS 1204X 4406
135.8. SYSTEM II ELECTRONIC CONTROL MODULE (WIRE GUIDANCE)
135.9. TRANSISTOR RESISTANCE
135.10. SYSTEM II WIRE GUIDANCE SPECIFICATIONS
135.11. HYDRAULIC SYSTEM
135.12. TORQUE SPECIFICATIONS
136.
136.1. FIGURE 1. HYDRAULIC SCHEMATIC
136.2. FIGURE 2. SCHEMATIC DIAGRAM WITHOUT WIRE GUIDANCE
136.3. FIGURE 3. WIRING DIAGRAM WITHOUT WIRE GUIDANCE
136.4. FIGURE 4. INSTRUMENT PANEL WIRING WITHOUT WIRE GUIDANCE
136.5. FIGURE 5. SCHEMATIC DIAGRAM WITH WIRE GUIDANCE
136.6. FIGURE 6. WIRING DIAGRAM WITH WIRE GUIDANCE
136.7. FIGURE 7. INSTRUMENT PANEL WIRING WITH WIRE GUIDANCE
136.8. FIGURE 8. DETAIL DIAGRAM
136.9. FIGURE 9. ACCESSORY WIRING DETAIL DIAGRAM
136.10. FIGURE 10. WIRING GUIDANCE CABLING AND DETAIL DIAGRAM
137.
137.1. WIRING SCHEMATIC-EPS III
137.2. OPTIONS SCHEMATIC-EPS III
137.3. WIRING DIAGRAM-EPS III
137.4. OPTIONAL DIAGRAM-EPS III
137.5. HYDRAULIC SCHEMATIC
138.

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